78 Kadett C Saloon - Beige, low and Turbo

[Count Vaux Alot]

Evening people thought i would share this with those that are interested


After having to sell my last Kadett I have wanted for nothing else other than another one so after some searching I treated myself and brought this one.

Currently it has long tax and mot and was in use daily although it still has reasonably low mileage (in the 40's).
It has some issues (as they all do) however they are mainly cosmetic. Most of them are the result of the previous owner’s efforts to 'repair' read as hide the beginnings of rust.

Here are some crappy mobile pics from the day I collected it to get you started - can you believe its a mid october day!?


http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/cc255248.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/0f755374.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/ecf11dd6.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/8d809677.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/808fe0e2.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/cc255248.jpg

It appears to be solid in all the right places, I havnt had a propper dig yet though ::)

[Count Vaux Alot]

Some of you will have seen this before but for those who havent here's a bit of back ground and some plans

Engine wise I'm going to go with the same engine I was going to fit in my last kadett (1.6 16v xe turbo) Its basically the 1.6 16v head, block and crank (from the likes of the mid ninties corsa and astra) with corsa vxr rods, pistons and under piston oil squirters and some stand alone management.
The block needs a slight over bore which ive already had done, and i'm most likely to be going with a Garrett GT2560 ball bearing turbo although the corsa vxr turbo does fit the head.

The inlet manifold will need to be a custom job as the 1600xe inlet is useful for nothing and the corsa vxr inlet doesnt fit the 1600xe head (yes I have tried).

The 1600 16v engines are lighter, cheaper and more readily available than the commonly used C20LET 2lt 16v turbo engine so they seem like a good alternative
I will be keeping the from the 1600xe

1600xe block

http://i248.photobucket.com/albums/gg167/Count85/Opel%20Kadett%20C%20wagon/Kadettestate022.jpg

http://i248.photobucket.com/albums/gg167/Count85/Opel%20Kadett%20C%20wagon/Kadettestate023.jpg

http://i248.photobucket.com/albums/gg167/Count85/Opel%20Kadett%20C%20wagon/Kadettestate025.jpg

The block fitted in the old kadett with a manta 1800 gearbox (im not sure whether to use a manta box or a stronger omega box at this point)

http://i248.photobucket.com/albums/gg167/Count85/Opel%20Kadett%20C%20wagon/Kadettestate034.jpg

http://i248.photobucket.com/albums/gg167/Count85/Opel%20Kadett%20C%20wagon/Kadettestate035.jpg

I'm was really happy with the space around the engine and box

http://i248.photobucket.com/albums/gg167/Count85/Opel%20Kadett%20C%20wagon/Kadettestate036.jpg

http://i248.photobucket.com/albums/gg167/Count85/Opel%20Kadett%20C%20wagon/Kadettestate037.jpg

And a comparison of the vxr piston and a standard 1600xe piston

http://i248.photobucket.com/albums/gg167/Count85/Track%20day%20nova/1600turbo013.jpg

http://i248.photobucket.com/albums/gg167/Count85/Track%20day%20nova/1600turbo014.jpg

http://i248.photobucket.com/albums/gg167/Count85/Track%20day%20nova/1600turbo015.jpg

Here is the intercooler I plan to use (pictured in my old kadett)

http://i248.photobucket.com/albums/gg167/Count85/Opel%20Kadett%20C%20wagon/Kadettestate065.jpg

http://i248.photobucket.com/albums/gg167/Count85/Opel%20Kadett%20C%20wagon/Kadettestate066.jpg

Core size is 500mm x 320mm x 90mm and its bang on

http://i248.photobucket.com/albums/gg167/Count85/Opel%20Kadett%20C%20wagon/Kadettestate067.jpg

http://i248.photobucket.com/albums/gg167/Count85/Opel%20Kadett%20C%20wagon/Kadettestate068.jpg

http://i248.photobucket.com/albums/gg167/Count85/Opel%20Kadett%20C%20wagon/Kadettestate069.jpg

[Count Vaux Alot]

This is how it looks in the car after some choppy choppy

http://i248.photobucket.com/albums/gg167/Count85/Opel%20Kadett%20C%20wagon/Kadettestate088.jpg

Back to the actual build in hand - I don't want to go ripping the engine out of the car straight away until I have all the bits I need to get most of the way through the engine conversion so I decided to get on with what I could.

Here's the engine on the stand with the old turbo (the corsa vxr unit) and my first unfinished attempt at the engine mounts. I wasn't happy with the engine mounts so I decided to take a different approach.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6904.jpg

O/S mount

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6905.jpg

N/S mount and vxr turbo

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6906.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6907.jpg

This is what I had to begine with - ugly as sin!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6926.jpg

And a selection of mounting holes to chose from

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6927.jpg

Now bare with me here but I started with nothing less than a land rover halfshaft as it happened to be exactly the right size (and it was lying around asking to be cut up)

So here it is with the end cut off

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/11377dfd.jpg

Then in the lathe

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/9a4c8b98.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/e6e5cfb1.jpg

Centre drilled, 6mm the 10mm

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/c5a15c2b.jpg

Then to 16mm

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/b3051219.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/f7cc14d4.jpg

Cleaned it up

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/c76c5f88.jpg

[Leeboo]

Cool... pictures look like they have been taken back in the day when it was new!

[Count Vaux Alot]

And put a taper on the front edge then parted it off

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/f19a37e7.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/9aefd6a0.jpg

Then put a taper on the back

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/83896f95.jpg

The first 3

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/f83e0848.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/3f3f19b1.jpg

Bolted the first 3 to the block (the bolts are just for set up I will use M10 allen head fixings)

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6928.jpg

Can you see were i'm going with this?

Started profiling up some tube

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6929.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6930.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6932.jpg

The first 3 tubes in place

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6934.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6935.jpg

Then tacked

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6937.jpg

And welded

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6940.jpg

Penetration

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6944.jpg

[Count Vaux Alot]

I then refitted the original mount to get the correct position of the mounting point on the cars cross member

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6948.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6951.jpg

Cut this ring out with a hole saw

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6952.jpg

And another piece of tube

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6953.jpg

Tacked that in place

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6954.jpg

I will now be able to triangulate off of the engine to the mounting point on the cross member

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6957.jpg

More to follow

[Count Vaux Alot]

I made the beginnings of the other engine mount, which turned out well

X 3 block spacers

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6959.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6960.jpg

That go on this side

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6966.jpg

Like so

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6967.jpg

I also took delivery of one 225hp Audi tt inlet manifold for modification (i only want the plenum part)

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6968.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6969.jpg

Its the right shape and has the curvature at the end I was after

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6970.jpg

I'm combining it with a third of the original manifold

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6915.jpg

To make things fit were I want them to there needs to be some savagery

Chop chop

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6919.jpg

So this can go here (ish)

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6972.jpg

After some more chopping I realised the spacing of the runners was right but the shape of the runners wasn't going to work together

Almost spot on spacing

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6975.jpg

Round hole to oval wasn't good

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6976.jpg

So I moved to the linisher and flattened off the face of the original manifold

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/9a326383.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/4b2afde2.jpg

[Count Vaux Alot]

Only to realise the port closest to you in the pic below sits higher that the rest

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/bff7aee6.jpg

I went from this

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/52ee268b.jpg

to this

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/ca9f3446.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/6cb6e2ca.jpg

To this

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/dd95f4c1.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/21d2d69d.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/3d2a289d.jpg

So I could start with a flat piece of 10mm aluminium plate

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/3ee849eb.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/b897fd7e.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/218b15bb.jpg

This will alloy me to weld the original inlet to the plenum and not have to worry about filling gaps and spaces between runners etc.

Next job is to mill out the ports in the ali plate then profile the edges and get it all welded together :)

[Count Vaux Alot]

I went to the tyre garage to get some new tyres on my wheels this morning

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6980.jpg

Then made my way to the workshop to get on with fitting them like a giddy school girl ::)

Rear end in the air and on axle stands

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6981.jpg

Inner arches looked better than expected

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6983.jpg

While I was fitting the wheels I thought it would be rude not to get the slam stick out and give it a beating

Rears done

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6984.jpg

Then annoyingly it got dark - however slam stick results were good!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6989.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6990.jpg

What do you think?

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6994.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7003.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7004.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7005.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7009.jpg

I forgot to mention at the beginning that the car came with a mounty steering wheel and a selection of TIM guages - I like the guages but not the wheel so much

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7012.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7013.jpg

[Count Vaux Alot]

And a couple of the other side if you haven't seen enough already

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7019.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7022.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7015.jpg

And finally two moody ones

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7025.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7026.jpg

After finishing the wheels I headed inside to continue with the engine mounts.

Firstly (as with the other side) I began to cut and profile the bars for the inner triangulation

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7027.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7028.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7029.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7030.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7031.jpg

Once I was happy with the bars I cleaned off the rough edges ready for welding

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7033.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7034.jpg

cleaned off

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7035.jpg

Tacked in place

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7036.jpg

[Count Vaux Alot]

Then began welding it in properly

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7039.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7041.jpg

I then began cleaning off some of the welds ready for then triangulation to the rubber engine mounts

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7042.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7043.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7047.jpg

And the two from above

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7045.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7046.jpg


I got out and did 40miles in the car today and it was as good as gold, even the missus didn't mind it. Had a few strange looks in sainsburys car park too!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/e38310ff.jpg

When I got home I went up the workshop to carry on with the engine mounts.

I flipped the O/S mount over to finish we;ding it up

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7048.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7049.jpg

Ive been using MIG but TIG would have made a neater job, unfortunately I don't have access to a TIG welder so that's that

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7050.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7051.jpg

the new mount clears the water pipe fine

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7054.jpg

Then it was back to the other side, where I welded round the tubing that sits on top of the rubber engine mount

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7055.jpg

[Count Vaux Alot]

Zap

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7057.jpg

And started on the triangulation to it - at which point my electric ran out so that was the end of that!

The last pic was in the dark >:(

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7060.jpg

Greetings good people!

I had a couple of spare hours after work tonight so I got on with the inlet manifold.

I started with this

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/b042c00d.jpg

I needed to lower the edge closest in the pic so the plate sat flush with the plenum

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/a724db1f.jpg

So I removed this pesky beast and did some more fettling

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/34979707.jpg

Getting there

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/1df67774.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/61bb4e01.jpg

Turning my attention to the manifold its self I removed this water way as it was in the way

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/3cdedcf3.jpg

I will address this mess later

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/dcb57e70.jpg

With that out of the way I could linish the manifold flat and to the required angle

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/5ee2c5a9.jpg

As so

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/00fb9474.jpg

Allowing the plenum sit like this

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/0e830572.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/b4c8ce3e.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/2dc1d3da.jpg

[Count Vaux Alot]

Getting fed up of holding it I decided to zip tie it in place so I could take some better pics and a few measurements

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/e4671ed3.jpg

I'm happy with the way it is sitting now

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/e58865b9.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/9928f7c0.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/3018dcee.jpg

Volvo 4 pots stripped

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/a7c0072f.jpg

De greased

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/0971eb74.jpg

Hot washed

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/bfb1576c.jpg

And dried

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/0697cc00.jpg

Looking much better and ready for some further cleaning

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/37ad747c.jpg

Then back to the manifold - marked the important areas out

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/eed06b83.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/e2edbf67.jpg

Card board lends a hand

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/1efaef21.jpg

All marked out

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/0d242451.jpg

on to the mill

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/c2969fa7.jpg

Test run

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/d6c8af88.jpg

[Count Vaux Alot]

First one done

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/c34d5a21.jpg

Then there were 3

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/c1f1a8ff.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/b3541d2f.jpg

stage one complete

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/9dd7fdd1.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/ba6993fa.jpg

Then put a nice chamfered profile on the edges

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/836f6153.jpg

Stage two complete

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/ff242579.jpg

It came out ok for a 'by eye effort'

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/494b5675.jpg

The plate goes here on the manifold

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/c0425fac.jpg

And looks like this inside the plenum

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/fa55ec37.jpg

I will probably finish the profile by hand to get them spot on

Thanks for looking

James

[Gibbo]

some top work mate.love the wheels

[_Jake]

very nice work on the plenum there, but please stop the dotty start/stop welding with the MIG its dangerous!

[Gibbo]

, but please stop the dotty start/stop welding with the MIG its dangerous!
why is that ?

[_Jake]

why is that ?
Its not really welding is it, Because 9times out of 10 by the time you've arc'd up and then let off again, it will not of been hot enough to penetrate. TIG should look like that but MIG should be one nice continuous weld... like so:
http://www.jnc-welding.com/Welder-Sheffield-Images/Welder-Welding/MIG-Weld.jpg

and TIG:
http://stainless-inox.net/wp-content/uploads/2011/06/tig-welding-steel-welderseries-2.jpg

[Nova_Tek]

Superb fabrication skills... this really is custom. Wheels really suit the car, definitely a unique build. :thumb:

[Count Vaux Alot]

very nice work on the plenum there, but please stop the dotty start/stop welding with the MIG its dangerous!

Oh please!

[_Jake]

Oh please!
Wasnt having a go, only trying to help...

[scott.parker]

Love this project mate, very awesome! Inspiring..

[Leeboo]

Your fabrication skills set it apart from most others, effort that I'd imagine will be recognised by (an important) few. Nice job on the inlet.

[John]

Wow! Awesome skills James! What happened to the red one? :)

[Count Vaux Alot]

Its not really welding is it, Because 9times out of 10 by the time you've arc'd up and then let off again, it will not of been hot enough to penetrate. TIG should look like that but MIG should be one nice continuous weld...


You may have been trying to help but trust me there is pleanty of penetration, its not dangerous - the whole reason i've chosen to pulse the welder in this way is because the tube is thin and i dont want to blow through all the time.

You can see the discolouration in the thicker hardened prop material i used as the block spacers

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF6943.jpg

Even after having wire brushed the worst off

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7050.jpg

The MIG you quoted in your pic is machine mig and there is no way you could weld round the tube ive been welding with such concistency all in one go with out blowing through the thin pipe.

[Count Vaux Alot]

Wow! Awesome skills James! What happened to the red one? :)

Sold it a while back, i had no space for it and i wasn't going to let it sit outside. I should have kept it really but it was the furthest behind of all the bits i had going on at the time and needed a few pennies worth of new panels too!

[John]

Ahh i see. is the porker done?

[Count Vaux Alot]

Nearly - wana buy it lol

[scott.parker]

What ever happened to the old nova you got the loon arches for?

[cossienova]

Billiant project with some ace fabrication going on there! engine looked impressive as it was when i seen it when i collected parts off you.That looks a good solid base you got there.

[steviegsi]

I want your workshop!

Car looks great slammed ! Look forward to updates.

[shed-on-wheels]

love this project fella looks amaizing great skills you have to ;)

[Rickyb]

im defo loving this just hope it doesnt get put to one side like the others.
great work.
rick

[Old man Jimbo]

I'm loving this one.

a) I remember when I was a boy we used to wang round in such cars.

b) The fab work I love.

c) Workshop envy!

Is that your own workshop for fun times or is that what you do for a job and you work from there??

:thumb:

[ben doodar]

Your engineering skills never fail to impress me. As soon as I noticed your new project I knew it would be a good read.

Do you still have the beige nova?

Lol how many different cars have you planned to put that 16xe in? Lol

[scott.parker]

Your engineering skills never fail to impress me. As soon as I noticed your new project I knew it would be a good read.

Do you still have the beige nova?

Lol how many different cars have you planned to put that 16xe in? Lol

Thats what i want to know Ben, the one he planed on putting loon arches on etc.

[Count Vaux Alot]

Now now gents calm your selfs! I still have the nova its just awaiting another engine (any suggestions for something interesting??) of some sorts (this is the 4th car the engine has been intended for lol)

Thanks for all your comments btw i will try and get this one done (no promises...)

There are two workshops in the pics ones my own personal one and the other is the firm i work for, i'm spoiled :)

[Southie]

Ah I'll subscribe to this, I need something exciting to read over the winter months James ;)

[_Jake]

The MIG you quoted in your pic is machine mig and there is no way you could weld round the tube ive been welding with such concistency all in one go with out blowing through the thin pipe.
Fair enough pal everyone does everything differently :) & it is possible just takes a lot of practise!

[peester]

ide have small block turbo'd the nova then gone with a big block for the kad c, but thats just me. Glad to hear the porsche project is near completion.

[Count Vaux Alot]

ide have small block turbo'd the nova then gone with a big block for the kad c, but thats just me. Glad to hear the porsche project is near completion.

So would I but I don't have the cash lying around to be building two expensive engines at once! So this is the compromise for the mo.

[Count Vaux Alot]

I've made a small amount of progress with the manifold however i have been working on my 944 today so i haven't had any time for the Kadett >:(

Manifold progress

I machined this edge off to help the air flow inside the manifold

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/5a04ecbc.jpg

Then chopped off the excess Ali from the back plate (annoyingly my plasma needs a new tip so it was a pita to cut up neatly)

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/ccb80322.jpg

And neatened it up a little - nearly ready for welding!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/e31f4ecc.jpg

[MattBrown]

Looks really good james.

Im sure you know how to use a welder by now lol

[calibra-keith]

i will be keeping an eye on this, mainly for the engine as i have been on about fitting vxr turbo/mani, pistons to my 16xe looked all over the net with dead ends, i didn't know about rods tho i was lead to believe cant use vxr rods.

[Mazz]

Sir, I tip my hat at your skills (as usual)

Sterling work as ever..

[burgo]

james i love you

[Balley]

Looking Beautiful as ever!

[Count Vaux Alot]

Thanks chaps. Burgo I love you too. Keith were did you find that info?

[scott.parker]

Umm c/x16xe turbo, very very tempting...

[calibra-keith]

i may have that wrong now i think about it think i got it wrong way round, i will try find the sites/info to double check, i had them saved but my harddrive packed in a week ago so need to hunt for loads of things again myself, saying that you have the bits to try out im only going by sites/forums these could be wrong anyway.

[Count Vaux Alot]

Well its been a busy week so far however there is always some time some were to do a little.

It was time to go back to the calipers, this is what i started with

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/37ad747c-1.jpg

here are the 'delicate surfaces' that need cleaning

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/c41c8d7e.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/ae0605ee.jpg

To do this I'm using fine sand as the blast media

The results

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/c68cd6e1.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/e76a4abf.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/17b4b678.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/92ff3ba5.jpg

Then i taped all these surfaces with gaffer (as its the stickiest and most durable) in preparation for some more abrasive blasting, stainless steel shot this time.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/638e35d3.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/09e5956f.jpg

Finally the finished result - much cleaner!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/a16e311d.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/d837c7fb.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/8a60470c.jpg

The cleaning really brings out the casting details

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/2a8f1b6b.jpg

I will paint these once I've sourced some new pistons (any one know a good supplier???) but for the time being i spray greased them and bagged them.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/cb6334ed.jpg

Thanks for looking

[Count Vaux Alot]

i may have that wrong now i think about it think i got it wrong way round, i will try find the sites/info to double check, i had them saved but my harddrive packed in a week ago so need to hunt for loads of things again myself, saying that you have the bits to try out im only going by sites/forums these could be wrong anyway.

I know i have the bits and they are all built in to the bottom end so they must fit lol i was just curious as to where you had come across the info. You are correct that the pistons don't fid the standard 1600xe block it needs a slight over bore.

[calibra-keith]

2 of them with a little info was vaux forums im sure it was MIG and one of the corsa forums, somewhere said the vxr rod may not fit 16xe crank but you can confirm this, and vxr piston wont fit 16xe rod, pin size slightly different but if the vxr rod and piston fits like you can confirm then thats that sorted, and a similar thread showing pictures of the turbo/mani clearance is tight even with relo kit and plenty of comments of the vxr turbo been weak advising custom mani for turbo better suited.

the info you have posted is the same and as far as i got to finding out so my eyes are on you lol

[Count Vaux Alot]

Manifold update time!

I started here some major tidying up needed

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7144.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7145.jpg

I need to chop the centres out between the runners

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7146.jpg

Chopped

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7147.jpg

And cleaned up

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7148.jpg

Then i moved on to the EGR arrangement, I cut it off and cleaned that up too

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7150.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7152.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7154.jpg

Cleaned up the inner edge of the runners

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7156.jpg

Smoothed out the edges of the inlet holes

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7157.jpg

Then V'd up the edges ready for welding

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7160.jpg

Prior to welding i wanted to blast the bits to make them nice and clean

Before

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7163.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7165.jpg

In the blaster

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7166.jpg

[Count Vaux Alot]

All done

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7169.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7172.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7173.jpg

Then it was off to the welders (unfortunately i don't have the gear to weld Ali )

It came back like this

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/e0534346.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/bd0cf02a.jpg

I'm really pleased, all it needs now is some cleaning off ;D

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/6804d8f7.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/f62b6ef3.jpg

This is how it look bolted up to the head - nearly OEM

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/30677e21.jpg

And with the fuel rail

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/f3fe77ad.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/4df3465b.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/9e0772a6.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/05a8197b.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/db1f356b.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/9c5125b9.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/5754d050.jpg

Sorry for all the pics

James

[Graeme]

Excellent skills there James whats the plan for getting at the inlet on the fuel rail?

[scott.parker]

That looks well good mate!

[Balley]

Inlet looks amazing. I shall be doing mine similar. Looks to have welding nice to for cast ****e..

[Count Vaux Alot]

Excellent skills there James whats the plan for getting at the inlet on the fuel rail?

Thanks Graeme i'm not sure if i will even use the original fuel rail as i wont be using standard injectors however if i do there are a couple of different fuel rails (or at least i have two different types) and i havn't tried the other one yet or i will modify one of the standard ones.


That looks well good mate!

Cheers dude


Inlet looks amazing. I shall be doing mine similar. Looks to have welding nice to for cast ****e..

The guy who welded it (thanks again Dennis!) is very good!

[Count Vaux Alot]

Inlet looks amazing. I shall be doing mine similar.

Why arn't you using the N/A inlet i wouldn't be going to all this if i could get hold of one that would work.

[scott.parker]

Is it an 16Xe inlet? will a 20XE rail fit?

[Balley]

Why arn't you using the N/A inlet i wouldn't be going to all this if i could get hold of one that would work.

There is no room in a Nova bay to have the intake on the left as the header tank is fairly large amd in the way as is the feed to the alternator and the vacuum pipe. Not saying it can't be done but I just don't think it fits that well etc.

[Benn]

Glad to see you back on this now, good work. Nova after this?

[Count Vaux Alot]

There is no room in a Nova bay to have the intake on the left as the header tank is fairly large amd in the way as is the feed to the alternator and the vacuum pipe. Not saying it can't be done but I just don't think it fits that well etc.

I think you will find the inlet doesn't have to be on the left, you can split the inlet in two turn the top round and have the seam welded up (you need to weld the seam as iirc the two bolt holes in the middle are off set so wont line up, i can't be 100% and you might get away with it) but the few mods you would have to make to it would be much easier than starting from scratch.
I will double check this next time i'm up the workshop if you want as i have an inlet up there?

[Count Vaux Alot]

Is it an 16Xe inlet? will a 20XE rail fit?

No ideal lol


Glad to see you back on this now, good work. Nova after this?

Back on it? when did i leave?? lol i might do the nova after this yer.

[John]

Mmmm manifold p0rn!

[Balley]

I think you will find the inlet doesn't have to be on the left, you can split the inlet in two turn the top round and have the seam welded up (you need to weld the seam as iirc the two bolt holes in the middle are off set so wont line up, i can't be 100% and you might get away with it) but the few mods you would have to make to it would be much easier than starting from scratch.
I will double check this next time i'm up the workshop if you want as i have an inlet up there?

Yeah thought this might of been possible. but wasn't sure and didnt want to buy one if it wouldnt work when I have three Inlets of a TD I can cut up. Could you find out please, and would it be forsale. Dan

[Benn]

Back on it? when did i leave?? lol i might do the nova after this yer.

Edit this, thought this was the red one you had put away in storage or something, didn't know this was another new start...

Now having fully read the thread, as always awesome work dude, amazing fab skills too.

[Adam]

Stunning build thread as usual mate!
Some awesome work, pretty handy having access to all the fancy tools :cool:

Loving this pic
http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/e38310ff.jpg

Interesting engine choice, inlet looks a superb bit of work! :thumb:

[nova_niek]

All done

<snip>

Sorry for all the pics

James

Que? Since when do we apologise for posting pics? lol

Top work there James - keep it up. Loving the intake manifold! :thumb::thumb::thumb:

[Southie]

Yet another decent/cracking build but please finish this one lol

[Danny s-p]

this look really nice

[Count Vaux Alot]

Presents arrived today ;D

What could this be??

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/6c73d1e8.jpg

You guessed it - yep omega 3Ltr V6 box. R25 - R28

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/44b09ded.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/1562f64d.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/919bd0c1.jpg

along with these

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/04012393.jpg

Selector

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/b52d8261.jpg

Rear box support bracket

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/7c93686f.jpg

Release mechanism

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/aa7d6ef0.jpg

Let the fun begin!

[scott.parker]

Bloody hell, whats your plans?

[Count Vaux Alot]

Hi People!

Thought i would add a couple of pics of the car all together before i start the engine fitment.

Here goes

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7275.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7276.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7277.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7278.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7279.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7282.jpg

And in the workshop ready for her new heart ;D

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7293.jpg

Balley

The TD manifold works the other way round and it wouldn't need much for it to just bolt together as it would the right way round. only a little hole elongating (sp) to the centre bolt holes that hold the two halfs together.

This is it the wrong way round

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7286.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7287.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7288.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7289.jpg

[Connor]

That is awesome!! :cool:

[Benn]

Stunning, looks awesome here.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7275.jpg


If you dont finish it, i'll punch you in the balls.

[Balley]

Cheers Dude. I will get looking for one..

[Count Vaux Alot]

Evening all.

Thought i would bring you up to speed with todays activities.

As i mentioned i picked up this scimitar axle, its a very suitable width and will take a jag powerlok diff

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7331.jpg

crispy

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7334.jpg

I also gathered this Porsche 944 throttle body to see if it would be suitable for use on my manifold

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7332.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7333.jpg

I then got side tracked by this corsa I'm breaking, tame you may think

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7335.jpg

But what is hiding beneath??

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7336.jpg

I extracted this pedal and servo from the corsa for the Kadett

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7339.jpg

With most of what i wanted to do with the corsa out of the way i turned my attention back to the axle.

Got it on the stands

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7352.jpg

And set about removing the unwanted bits as they are in the wrong place

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7353.jpg

first i used the plasma cutter

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7354.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7356.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7357.jpg

Then tidied it up using the grinder

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7358.jpg

smoothed off

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7361.jpg

on both sides

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7360.jpg

[Count Vaux Alot]

and a quick DA

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7362.jpg

And some acid etch primer

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7365.jpg

while that axle was drying i moved on to the Kadett - engine removal time!!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7403.jpg

It looks like there is enough room in there to get in there with it

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7404.jpg

Rad removed

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7405.jpg

along with the dust bin style airfilter housing and some wiring

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7406.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7407.jpg

More soon

James

[Gibbo]

nice work. looks like theres a c20let in corsa ?

[Rickyb]

Need more, your work is like a drug I'm soooooo addicted lol
Rick

[Benn]

So it's gonna get a turbo lump too? Nice! I wanna see this unit at some point...

[Count Vaux Alot]

Yer Benn it's going to be turbo but not a let, you should pop over at some point and say hi.

[Count Vaux Alot]

Got on with the Kadett again tonight, small steps and all that :D

It was the coldest the workshop had been for a little while (when I've actually been there anyway)

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7416.jpg

I spent a while fiddling about undoing various nuts, bolts, wires, pipes and cables before i actually managed to get the trusted seat belt and engine crane connected to the engine.

as so

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7417.jpg

After some wrestling i achieved liberation of the engine

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7420.jpg

and the gear box as well - i would have thought its been a while since the engine and box weren't attached to the car or each other.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7422.jpg

finally i disconnected the prop too so i can start to trial fit the new engine and box combo. It looks like a war zone under there lol

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7423.jpg

Thanks for looking

[Rickyb]

woo woo i absolutly love this car.
keep the great updates coming

[Count Vaux Alot]

Some more progress tonight ;D

I got the engine off the stand

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7424.jpg

took the mount off the back of the gearbox

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7425.jpg

and for the first time combined the two - they fit together thank fook

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7426.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7427.jpg

like it grew there

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7428.jpg

Then for some unknown reason i decided to see how heavy the pair of them were so i stuck them on my shoulder and lifted

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7429.jpg

It turns out they aren't as heavy as you would think - however the engine crane is a lot better at it than i am ::)

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7433.jpg

Up

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7434.jpg

Over and in

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7436.jpg

Next step is to get it all sitting were it should.

Thanks James

[scott.parker]

You sir are my hero!

[Count Vaux Alot]

Thanks Scott lol

[scott.parker]

Thanks Scott lol

Build me a small block turbo for nothing and ill love you forever! lol

Need inspiring for my loon, and this is it's "older" brother! lol

[Austin_Nova16]

Looking awsome!
Loving the manifold!
Good choice on the Omega Box (Thats what I've gone for in the Cortina!).

Keep it up!

[peester]

well 'ard.

[Linch]

Amazing! Love the work on the inlet manifold! and the mounts! smallblock turbo awsomeness!

[David2005]

I'm loving this build but please finish off the Nova build as I loved that too. You going to have to use a spacer for the release bearing in the box? Whats your plan on setting up the hydraulics?

[Benn]

Yer Benn it's going to be turbo but not a let, you should pop over at some point and say hi.


I will when you say where your hiding it... lol

[Count Vaux Alot]

Thanks chaps - Benn give me a txt if you do want to pop over


Looking awsome!
Loving the manifold!
Good choice on the Omega Box (Thats what I've gone for in the Cortina!).

Keep it up!

Thanks Austin any details anywere of said cortina? what did you do about the clutch release machanism? dids you keep it hydraulic?




well 'ard.

Hard by name and all that lol

[Nobby]

fukin awesome mate i wonder how many other forums this will appear on?

[Count Vaux Alot]

Hi All,

Had a bit of a session Saturday afternoon

This bracket was in the way so i removed it

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7437.jpg

then it was off with the old engine mounts, one was a little bastid!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7438.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7441.jpg

then the other side

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7440.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7439.jpg

I ended up cutting the rubber and beating it un done with these

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7442.jpg

back out with the engine and up in the air with the car to gain access to the gearbox tunnel as i needed to remove the original brackets to create some much needed room for the box.

as so

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7447.jpg

and back in with the engine, i fitted the old engine mounts to see if the positioning was any were close and unfortunately with the omega box (as opposed to the manta box) the position is wrong. The engine needs co come forward and down.

Tight on both sides up front

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7451.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7466.jpg

New engine mount rubbers fitted

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7454.jpg

bonnet off

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7458.jpg

engine out again and the car on stands this time so i can actually see under it while trying to position the engine and box.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7459.jpg

engine up and back in again (then back on with the original mounts just to check the clearances again)

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7461.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7462.jpg

This is the situation with the gearbox at the back

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7475.jpg

[Count Vaux Alot]

not too bad on the N/S

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7476.jpg

quite close on the O/S but not the worst, so the clearance issue is at the front of the gearbox tunnel

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7477.jpg

I then stuck the head on to see how much further forward the block needed to be, as you can see the angle is all on the piss too so once the whole lot moves forward and i 'manipulate' the tunnel a little and possible lower it a little things should be sitting better.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7478.jpg

too close at the back, 50 mm forward should be fine

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7479.jpg

However i think it looks good sat in the bay

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7481.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7482.jpg

there is loads of room up front

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7484.jpg

and the inlet is sitting in a comfortable place

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7486.jpg

even with the throttle body attached

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7487.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7488.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7491.jpg

Needless to say I'm happy with the progress

Thanks for looking

[peester]

does look the bizz, for first trial fit.. Its as if you already knew lol.

[nova_stee]

Every kaddet and chevette ive seen has the tunnel modified to fit the omega box they dont fit right in

[scott.parker]

Very interesting, though it looks a right struggle by your self mate, so good on you for doing it.

Scott

[Count Vaux Alot]

Every kaddet and chevette ive seen has the tunnel modified to fit the omega box they dont fit right in

Yer i know I expected it not to fit

[Benn]

Looking good Jim, some bit of fab and she'll fit nicely in there..

[Nobby]

nomnomnom

[bazil]

Another awesome thread from yourself :)

Your inlet design is cracking, it's so good I may have to copy it lol,

[Count Vaux Alot]

Thanks guys :)

[Count Vaux Alot]

Hi heres the round up for this weekend

Bought a new welding mask (I'm not sure if i like it yet)

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7492.jpg

First up i set about removing the front carpet

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7493.jpg

making sure not to loose any of the fixings

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7494.jpg

I wanted to get at the offending gearbox tunnel

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7495.jpg

The carpets done well for 34 years of service

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7496.jpg

Is there supposed to be a lump of chip board here??

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7498.jpg

At this point i though oh toss whats it hiding, luckily nothing its quite tidy underneath

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7499.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7500.jpg

engine out again!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7502.jpg

to get to the underside of the tunnel so i could see what could be done about the lack of space

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7503.jpg

After much fecking about i decided to move on to something else (more on the tunnel later)

Here is the next offending area

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7504.jpg

time to fit the new Corsa B brake assembly - this one below \/

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7339.jpg

spot weld time

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7505.jpg

after a quick sand over they all became apparent and i drilled them out with little drama

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7506.jpg

a bit crispy underneath, that's not a problem!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7507.jpg

[Count Vaux Alot]

then it was out with the old brake assembly

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7508.jpg

to gain better access for some more drilling

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7511.jpg

I was careful with the important ones in the corner not to drill through.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7510.jpg

Time to get brave and cut a big hole - it will become clear why I've cut so much out

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7512.jpg

more spot welds successfully removed

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7514.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7515.jpg

part of the heater blower plastic needed removing

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7516.jpg

to gain access to cut out some more metal

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7517.jpg

So as seen when others have added the corsa B brake assembly (like Darcy's below) you need to raise the whole assembly to get the pedal height right without cutting the pedal arm etc.

http://i143.photobucket.com/albums/r132/coggers01/kadett/14042008109.jpg

http://i143.photobucket.com/albums/r132/coggers01/kadett/14042008111.jpg

to avoid having a raised platform area i want to raise the height of the whole area so it looks more original and strengthen it while I'm there.

I will be following this line

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7519.jpg

In order to do that it was necessary to chop some more

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7521.jpg

getting there now

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7522.jpg

all the spots behaving again

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7523.jpg

a quick sketch

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7520.jpg

[Count Vaux Alot]

ready to be transfer ed to 2mm sheet

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7524.jpg

I then had to move to my phone camera as the batteries on the other one went flat so pic quality isn't great from here on in.

I set the corsa B assembly up on a threaded rod so i could adjust the height to suite

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1685.jpg

then set about the lower part of the bulk head to remove the holes left by the old brake assembly and generally strengthen the area with some more 2mm

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1687.jpg

this lot needed cleaning off first

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1688.jpg

as so

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1689.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1691.jpg

area below the rule needs filling first

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1692.jpg

I started with this

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1693.jpg

Some bending

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1694.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1695.jpg

And welded that in

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1697.jpg

Stage two the top part, roughly marked out

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1703.jpg

more bending

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1704.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1706.jpg

i used a piece of box here instead of angle to get the correct radius

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1707.jpg

[Count Vaux Alot]

as so

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1709.jpg

Tweaked these edges up with the mole grips

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1711.jpg

so it fits here

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1713.jpg

as so

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1714.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1715.jpg

Drilled the spot weld holes

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1716.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1718.jpg

Cleaned the edges off and tacked it in

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1720.jpg

And some more welding

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1722.jpg

in nice and level

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1723.jpg

finished off the welding

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1725.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1726.jpg

It could have come out worse

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1727.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1728.jpg

Hopefully it mirrors the other side to a certain extent

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1730.jpg

[Count Vaux Alot]

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1731.jpg

Once its all sealed up it will blend in well

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1729.jpg

Thanks

James

[Rickyb]

love it keep it up buddy.

[burgo]

i hate you, i wish i was as good as you

[Balley]

Very Nice fabrication work pal :)

[The Simps]

Noice work as usual bud. Need to pull your finger out tho.

[MK999]

Need to pull your finger out tho.

Flol, the irony, it hurts!

Mainly because there's some in this post too :(

[Count Vaux Alot]

Thanks Cretins

[ben doodar]

Great work as always mate. its a pleasure to read.

[nova_niek]

It could have come out worse...

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/IMG_1727.jpg


You, sir, are a legend.
Being in the sheet metal business myself I know what it takes to bend 2mm steel plate. A 150 tonne press, that's what. And you do it with hand tools. Amazing. :thumb:
Love this thread!

Cheers,
Niek

p.s. can't spread the love right now, have to go tickle someone else first!

[Count Vaux Alot]

Ah look what arrived today :) thanks Coggers!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/45103a00.jpg

[Benn]

Awesome work as always James.

[farmertom]

Looking sexy that. What's the tunnel in the box from if you dont mind me asking?

[Southie]

Hats off James, cracking job as ever.

[Count Vaux Alot]

Looking sexy that. What's the tunnel in the box from if you dont mind me asking?

Ask away (every one else does lol) it's an auto tunnel for added girth for the Large omega box.

[Plug]

Looking good james fabrication is amazing as normal coming from your workshop,

[NOV4_SPORT]

Very nice indeed james buddy, the fabrication of the mounts and the inlet plenum and sheet metal as well as everything else it shows you have the skill especially with the tooling you are using buddy.

keep up the good work. +rep

iain

[scott.parker]

dude you never surprise me any more, your skills are some of the best Ive seen on here! wish i had the knowledge/patience and a unit tools etc to do it my self like you.
Top job dude..

[Count Vaux Alot]

Update from today - The quest continues

This is the temp in the workshop after 10 mins of the heater being on!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7525.jpg

Anyway despite the cold i did get on with a few bits. Here is the new auto gear box tunnel extra girth included

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7526.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7527.jpg

Its to go here

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7528.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7532.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7531.jpg

I uncovered the spot welds (as they were covered in black sound deadening sh!t)

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7534.jpg

and removed them

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7535.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7536.jpg

Leaving this

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7537.jpg

and a nice overlay template

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7542.jpg

I removed the front seats at this point so i could get this in here. Its large enough to cover the original tunnel!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7544.jpg

After some measuring and messing around i riveted the 'template' in plate ready for some grinding

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7547.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7548.jpg

Anti destroy the windows with grinding sparks tent erected inside the car

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7549.jpg

[Count Vaux Alot]

Then got brave and cut a fook off hole in the floor!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7552.jpg

Double trouble, check out the new girth!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7554.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7555.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7556.jpg

I tried the two tunnels on the gearbox

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7557.jpg

Much better

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7558.jpg

The auto tunnel fits a treat in its new home

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7560.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7563.jpg

In preparation for fitting the new tunnel i decided to attack the sound deadening inside the car

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7564.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7565.jpg

This stuff is horrible

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7567.jpg

I find a heat gun and a sharp scraper are best for removing it

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7568.jpg

getting there, removing it is quite satisfying

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7569.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7571.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7572.jpg

[Count Vaux Alot]

I set at the black cr@p on the new tunnel too

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7573.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7574.jpg

a wipe over with white spirit and these sticky remains will come off

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7575.jpg

flipped it over to deal with the huge bead of seam sealer around the edge

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7576.jpg

Gone

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7577.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7578.jpg

Then got the engine back in the car again

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7579.jpg

much easier to get at the box now

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7580.jpg

got the whole lot sitting right

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7581.jpg

Then (here's my theory) i set the Gauge to 4 degrees of level and adjusted the angle until the bubble was were it needed to be measuring of the square face of the front of the engine. This way the box output flange should be facing down by 4 degrees.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7584.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7589.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7586.jpg

Leaving the box sitting like so

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7590.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7591.jpg

[Count Vaux Alot]

i laid the auto tunnel in place with the box fitted and it covered it! You can just about make it out here

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7601.jpg

and i have around 60mm of clearance up front above the cross member - custom sump me thinks

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7592.jpg

Thanks for looking

James

[The Simps]

Smart as always James.

[scott.parker]

Again, never a dull mod! lol

And the sound deadening comes off a treat with heat and scrapers! Just dont let it set on fire! lol

[Count Vaux Alot]

I'm on the hunt for a Corsa c clutch pedal if anyone has one? Although I've had not time on the car today I should get the engine mounts sorted thus week :)

[Benn]

Coming along well James.

[TonySR]

Your work never fails to amaze me!


Ps. What happened to the nova? Or has it taken a back seat whilst this is being done?

[farmertom]

nice work with the new tunnel there. sound deadening is horrid stuff to get off even with a heat gun and sharp scraper.

[Count Vaux Alot]

Your work never fails to amaze me!


Ps. What happened to the nova? Or has it taken a back seat whilst this is being done?

Thanks Tony - I still have the nova and I haven't forgotten about it!

[Rickyb]

lovely bit of plan and design there keep the awsome updates coming :D
rick

[Count Vaux Alot]

I may be getting a bit a head of myself here as you do but I was thinking something like these for the seats (I don't know the cost yet either so that could play a significant part!)

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/9dfeac67.jpg

Only in this style of seat as I want harness holes

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/7cef5825.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/97e50971.jpg

[The Simps]

Looks comfy.

[ben doodar]

Awesome work as always mate.

The seats look retro cool but I'd hate to have a rear impact. Your neck would be in two!!

[scott.parker]

James seats look awesome mate, love them! i may need your help/advise dude, not sure if Ive still got your number, I dont think i do,can you PM me it?


Scott

[Count Vaux Alot]

Awesome work as always mate.

The seats look retro cool but I'd hate to have a rear impact. Your neck would be in two!!

Ben I should have made it clear that the seats with the harness holes have head rests too they just arnt pictured

[Count Vaux Alot]

James seats look awesome mate, love them! i may need your help/advise dude, not sure if Ive still got your number, I dont think i do,can you PM me it?


Scott

Pm'd mate :)

[Benn]

Tunnel is looking good, great work getting everything set up right in there.

Seats are nice.

[Count Vaux Alot]

Some progress from tonight

now the engine and box are were I want them to be its time to make them a more permanent fixture, however that's not as simple as just make the mounts. I need to alter the mounting position as the rubber part of the mount is sitting too high.

I want the rubbers lower

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7603.jpg

So the angle of the triangulation off the block is more suited to its purpose

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7604.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7605.jpg

Here's the mounting point on the cross member from below

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7607.jpg

chopped the top off to the desired height

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7608.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7609.jpg

as well as lowering the mounting point I also wanted to move it forward while I was there, in doing this the mount was coming closer to the steering race so I had to take that into account.

Anyway here's my efforts

I found a piece of pipe with a similar radius to the steering rack to use as a template

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7610.jpg

I started with a small piece of box section

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7611.jpg

then chopped this area out

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7612.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7613.jpg

Then chopped some more of the original mount away

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7614.jpg

for a trial fit

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7615.jpg

I then shaped the top of the new piece of mount to suite the angle of the original mount

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7616.jpg

[Count Vaux Alot]

and cut a small section out to clear a suspension mounting bolt

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7618.jpg

and filled the bottom of the new piece of mount in

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7619.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7620.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7621.jpg

welded it up

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7624.jpg

and cleaned it off

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7625.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7626.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7627.jpg

Another trial fit - reasonably happy with that

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7629.jpg

Then started on the top of the cross member mount

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7630.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7631.jpg

that plate will take the rubber mount, as so

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7632.jpg

and the plate will sit as so on the new piece of mount when its welded to the original cross member - simples!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7633.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7634.jpg

that's all for tonight

James

[peester]

christ.. on another level now.

[Jedro]

some seriously good fabrication and restoration work in here. love it

[Count Vaux Alot]

Cheers guys, i will hopfully crack on with the mounts at the weekend and get them sorted.

[Benn]

Your way to skilled.

[nova_niek]

I can't help myself... I just love this thread. :thumb::thumb::thumb::thumb::thumb::thumb::thumb:

[Count Vaux Alot]

Some tinkering from the weekend

I started were i had left of with the modifications to the cross member on the N/S

Drilled a hole for the rubber mount

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7635.jpg

and welded the nut on

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7636.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7639.jpg

Tacked the cross member extension in place

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7637.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7638.jpg

Then tacked that piece of plate to the cross member

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7640.jpg

Giving me a platform to build the rest of the engine mount off of

I started by shaping some more tube

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7641.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7642.jpg

to go here

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7644.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7645.jpg

making sure the gaps were good from all sides

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7646.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7647.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7648.jpg

Thinking at this point feck me its cold and it was!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7649.jpg

Anyway tacked that up
http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7650.jpg

[Count Vaux Alot]

moved on to the next

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7651.jpg

noting gaps again (mirror required this time)

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7652.jpg

Once those two links were securely in place i could remove the mount and work on it on the bench - much easier!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7653.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7654.jpg

welded those joins properly

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7655.jpg

and shaped and fitted the final piece of tube

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7657.jpg

welded home

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7658.jpg

it needs tidying up but it came out ok

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7660.jpg

Fits like this

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7662.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7663.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7664.jpg

Going back in time (after work on Friday) i took advantage of the mill (making hole sawing much easier) and cut this out

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/f8234625.jpg

Chomp

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/f7218de8.jpg

giving this

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/09c3fc14.jpg

then gave that a quick tidy up

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/405374dd.jpg

[Count Vaux Alot]

to go here on the O/S

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7665.jpg

as before the height of the cross member mounting point wasn't suitable

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7666.jpg

so i took this

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7667.jpg

chopped the top off (trying not to destroy the steering at the same time)

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7671.jpg

took a pattern

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7670.jpg

and shaped another plate to go on top

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7668.jpg

finilised the shape welding another nut on after wards

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7672.jpg

welded some tube to the disc i had cut previously

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7673.jpg

and tacked the piece of plate to the cross member checking for clearance around the steering joint.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7675.jpg

Some more pipe shaping and i had my first piece for this side in place

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7676.jpg

tacked

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7678.jpg

then out on to the bench for the second one

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7679.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7680.jpg

finally number three

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7682.jpg

welded home

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7683.jpg

[Count Vaux Alot]

tried for fit

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7684.jpg

One from above

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7685.jpg

i was happy with the results :) , as i said they need some tidying and a good painting too but they will do for mock up.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7686.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7687.jpg

Next was the gearbox, i only made a start on this so i will updateonce finished.

James

[mowgli]

Mr count, not one to criticize, as my welding & fab skills are somewhat lacking , but will the starter still fit ok on the rhs? As that mount looks quite meaty.

[therealnovaboy]

silly question. did you leave that washer on then weld on the captive nut?

if so whats the reason for doing this.

[Benn]

Awesome mount work.

[Count Vaux Alot]

Mr count, not one to criticize, as my welding & fab skills are somewhat lacking , but will the starter still fit ok on the rhs? As that mount looks quite meaty.

It should be fine mate as I checked before I started.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7032.jpg

[Count Vaux Alot]

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7041.jpg

[MK999]

silly question. did you leave that washer on then weld on the captive nut?

if so whats the reason for doing this.

No washer, it's a flanged nut.

Mounts look bomb proof, mini engine spaceframes lol Lots of power due? :d

[Balley]

Nice mount work James :)

[blue_peg_16v]

Awsome fab skills mate as always

[gazz]

brilliant fabrication going on there bud..top work..:thumb:
you must be going through some 1mm cutting disc's cutting all that plate too ;)

[Count Vaux Alot]

No washer, it's a flanged nut.

Mounts look bomb proof, mini engine spaceframes lol Lots of power due? :d

I will be aiming for 200hp to begin with then who knows from there, best to go over than under. They are surprisingly light too.

[Count Vaux Alot]

brilliant fabrication going on there bud..top work..:thumb:
you must be going through some 1mm cutting disc's cutting all that plate too ;)

The 1 mm discs have lasted longer than expected up until now however this is only the start!

[The Simps]

Gives those mounts to Benn for buftying :)

[Benn]

They'd come up nice i think...

[The Simps]

Awesome mount work.

Is it only me who slightly giggled when I read this?

[Count Vaux Alot]

Is it only me who slightly giggled when I read this?

Thanks for your input :roll:

[Count Vaux Alot]

Gives those mounts to Benn for buftying :)


They'd come up nice i think...

i'm not sure if polishing is the way forward here, i think i will clean up and paint, i have a colour in mind too :)

[Adam]

Stunning work!
Bet those mounts are strong as funk.

[MK999]

i'm not sure if polishing is the way forward here, i think i will clean up and paint, i have a colour in mind too :)

Mustard motherfcuking yellow :cool:

[fearless]

Loving the Fab work count - first class

One quick question which youve probably already answered

Not sure what Engine Management you'll be using - will you need a knock sensor ?

It looks like you may have used the mounting position between 2 & 3 cylinders for your engine mount on the Offside


I'm sure you've got this under control - everything else seems to be :)


Dave

[The Simps]

Thanks for your input :roll:

I was in no way commenting on your mounts, more the sexual connotation of what Benn said. Just to be clear. Your work is awesome as always.

[scott.parker]

James did you get my PM?

[Count Vaux Alot]

James did you get my PM?

Yes mate I haven't been on a pc to write a proper reply only my mobile, I will write a proper reply when I have the chance.

[Count Vaux Alot]

Some goodies have arrived!

Corsa C clutch pedal (as the omega box is hydraulic)

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/c39d43dd.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/699164fd.jpg

And the rubber mount for the gearbox

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/b118f362.jpg

[Rickyb]

i absolutly love this car you have some great fab skills. well done to you sir.

[Count Vaux Alot]

The Missus was on lates this weekend so its was the perfect opportunity to get up the workshop!

With the engine mounts as good as there other than some tidying up it was on with the gearbox mount.

Here's the original gearbox mount

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7688.jpg

frankly its not very supportive the rubber is super soft and twists easily by hand

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7689.jpg

so in steps its replacement or at least the starting point

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7690.jpg

i refitted the rubber doughnut to the box so i knew what space i had to work with

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7691.jpg

then set to a piece of 10mm plate

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7693.jpg

drilled a mounting point hole and threaded it

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7695.jpg

so the rubber would mount to it as so

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7696.jpg

Started shaping it up

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7697.jpg

added 2 mounting holes, this is were it attaches to the back of the box

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7698.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7699.jpg

Here

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7472-1.jpg

and put a step on the back edge to clear the doughnut

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7701.jpg

pic of it fitted, i hope you get the idea

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7718.jpg

next job was to make something for the rubber to sit on, i wanted to partially recess the rubber to try and make as much space for the exhaust as possible - i will let the pic explain as they are better at it than me!

Another hole

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/9d96dd8b.jpg

chopped up some pipe

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/c143551c.jpg

[Count Vaux Alot]

that sits as so

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/7b74a219.jpg

then this lot will go together to make the rest of the mount

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/fc06fab6.jpg

The rubber that attaches to the plate on the block sits in the hole

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/dd8e5ccd.jpg

as so

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/ee34f62c.jpg

on with getting it stuck together

V'd this edge out

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7707.jpg

and added some holes to puddle weld the ring in place with

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7708.jpg

welded it up both sides

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7709.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7710.jpg

Cleaned those bits up and got the positioning right on the car then tacked it in place

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7715.jpg

took it all back off the box to check it was as it should be

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7722.jpg

and welded it up

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7724.jpg

before i weld the rest in place i wanted to lighten it up - yep more holes

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7725.jpg

acid etch primed the back edges

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7727.jpg

splatted it together

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7728.jpg

[Count Vaux Alot]

and the other side

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7730.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7732.jpg

in the midst of this i borrowed a throttle pedal from a corsa B

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7736.jpg

Next was the 2 front triangles

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7739.jpg

welded them in and cleaned them off

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7740.jpg

flipped it over

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7741.jpg

and chopped out some more

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7743.jpg

added a central support

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7744.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7745.jpg

primed (for the time being)

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7747.jpg

and bolted it up - fits a treat and its quite neat

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7749.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7750.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7751.jpg

with the engine and box now supporting themselves i put the head back on to check clearance again - all good

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7754.jpg

[Count Vaux Alot]

even over the back although its tight

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7755.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7756.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7759.jpg

With everything sitting as it should i needed to modify the gear linkage, so out with the gearbox tunnel for better access

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7760.jpg

luckily i got the original gearstick and linkage with the box

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7761.jpg

so i decided to utilise as much of it as i could - refitted the original mounting bracket

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7762.jpg

pulled the linkage to bits

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7763.jpg

cut the 'U' off the old tube and reduced the tubes length by 175mm

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7764.jpg

replicating the pinch cut outs

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7765.jpg

and welded the U back in place

Next was the mounting plate cut and shut, again 175mm removed

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7766.jpg

welded the 2 together

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7767.jpg

and filled the gaps with bits of the waste material

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7769.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7770.jpg

then gave it a clean up and blend

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7771.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7772.jpg

[ben doodar]

Words fail me...

[scott.parker]

Your too good at this stuff! come do mine it's easy compared to yours! lol

[John]

Awesome stuff James :)

[nova_niek]

Love it! :-D

[Count Vaux Alot]

Cheers Chaps :)

[Ernie]

Didn't even know you had this. Nice one.

[NOV4_SPORT]

Good times mate, the mount looks amazing mate ! Keep up the good work

[Benn]

Funk you and your welding and fab skills.







*jelouse. Awesome work as always James. Will gearbox movement still clear the mount? (UJ wise) Loving this project dude.

[joff-turbo-nova]

Excellent read - well done on the fabrication skills !!!

Joff

[Count Vaux Alot]

Funk you and your welding and fab skills.
*jelouse. Awesome work as always James. Will gearbox movement still clear the mount? (UJ wise) Loving this project dude.

Thanks Benn - yes it will clear fine, althought it looks close. if you at the pic below (as i havent got one at the right angle with it fitted and finished) the rubber doughnut doesnt actuall drop down as far as the step i put in the back of the 10mm plate let alone past the rubber and down to the second mount.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7722.jpg

[Benn]

Ah, was a just in case thought.

[Count Vaux Alot]

Hi all, only a small update today despite spending over 6 hours at the workshop dithering about! just one of those days ::)

Anyway i got the shifter rebuilt and back on the box to check all was good, thankfully it was.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7790.jpg

Nothing was fouling and the shifters throw wasn't too bad

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7791.jpg

Next was making the shifter hole in the tunnel suite the new shifter - not as easy as first thought.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7792.jpg

chopped a bigger hole to see what i was working with

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7793.jpg

It quickly became obvious that the new shifter mounting bracket fouled the tunnel on both sides. More surgery needed.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7794.jpg

Spot welds uncovered

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7796.jpg

And drilled out

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7797.jpg

some measurements later gave me the beginnings of the new shifter hole

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7798.jpg

[Count Vaux Alot]

Bendy

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7799.jpg

cutty weldy

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7800.jpg

some smoothing

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7801.jpg

Some time later it was back in the hole

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7802.jpg

Originally I planned to make it out of one piece of metal but a slight miscalculation and some swearing later lead me to cut it in half and re join it. You wont notice once I'm finished (i hope)

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7803.jpg

it was beginning to take shape now though

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7804.jpg

so i got the hole cut for the shifter and left it at that

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7805.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7807.jpg

Thanks for looking

James

[16v Nova Kev]

such a cool project.

[Nobby]

im speechless dude ****ing epic

[Benn]

Nice work.

[Balley]

More impressive work pal!

[scott.parker]

Ha! James thats ace mate, just ace, i wish i had a unit and the tools to work on mine! so jealous mate!

[Count Vaux Alot]

The latest acquisition to the parts pile :)

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/9175b864.jpg

[Connor]

Just saw this pic on the net and it reminds me of this project so thought i would share...
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc7/420623_281622115240006_191733277562224_686286_9209 84086_n.jpg

[Count Vaux Alot]

Cheers Connor i'm glad you decided to share it!

[Connor]

I will share anymore if i come across any :thumb:

[scott.parker]

Thats awesome!, would love my loon to look like that! lol

[Count Vaux Alot]

I will share anymore if i come across any :thumb:

Was there a build thread or any info? I like the front lights :)

[Connor]

Nah it was on a random car facebook blog style thing, popped up on my newsfeed randomly.

[Liam]

It's a Photoshop. If you look at the wheels you can see how they are not cut out properly.

[Connor]

^i was thinking that, but thought it was me tripping out

[Count Vaux Alot]

I knew it was a photoshop, the rear wheel looks wierd and they are very wide and very low but i was on about the lights.

[burgo]

you know the problem with your threads james, you do everything to perfection and make me ashamed of my work so then i have to redo it.

[Benn]

^Snap.

[Count Vaux Alot]

Whats up peeps?!

Got up the workshop on Saturday and gave the place a god clean out as it needed it so so badly!

Then Sunday it was back on with the car.

Victim number one - the old sump

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7840.jpg

it needs to go here

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7841.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7842.jpg

yep you guessed it, it doesn't fit so, some sketching later

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7843.jpg

then some chopping

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7844.jpg

Yey it fits now

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7846.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7847.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7850.jpg

but it has a hole in it so will obviously need some work :D there is plenty of space down the N/S of the engine for the exhaust

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7848.jpg

and the space on the O/S will be filled with a wing add on to increase sump capacity

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7849.jpg

next job was to make some space up front for the intercooler and radiator.

here's what i had to start with

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7812.jpg

i need to fit this in there

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7825.jpg

removed the spot welds on the support brackets

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7814.jpg

and riddled the battery tray with holes

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7816.jpg

[Count Vaux Alot]

chopped that lot out

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7826.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7827.jpg

off with the rest of the battery tray and the horn bracket to clean things up a little making way for the boost pipework.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7828.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7829.jpg

there we go

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7830.jpg

happy there was the required amount of room now i put the head back on the engine to see if things would line up

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7832.jpg

with some fettling it should work well

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7833.jpg

Next on the list was finish off the gearbox tunnel

I began with this

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7835.jpg

Cut and shaped some metal

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7836.jpg

welded that in

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7837.jpg

and cleaned it off

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7838.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7839.jpg

cut the waste material off

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7852.jpg

and began to bend it a little to fit the tunnel

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7853.jpg

drilled some spot weld holes in the tunnel

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7854.jpg

[Count Vaux Alot]

then began to weld it all together

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7855.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7858.jpg

all done

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7859.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7860.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7861.jpg

engine back out again

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7862.jpg

victim number two, three and four - the rear seats, belts and carpet

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7864.jpg

Gone

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7865.jpg

i found a special repair not of my doing!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7867.jpg

cleaned up the edges around the gaping hole in the car and the edges of the gearbox tunnel

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7869.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7870.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7871.jpg

gave them both a quick coat of acid etch

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7872.jpg

and started to make the new tunnel a permanent feature

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7874.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7876.jpg

More soon

James

[gunny]

Looks good this Count, the extent you go to is amazing to be fair. Don't think I'll be putting this much effort into the Chevette lol fair play to you though

Edit: If you can get your hand on an R28 from a v6 i'd replace the R25-R28, a lot stronger box. Using one on mine.

[Benn]

J, where does the water rad go? Surely the IC has taken it's place...

[Count Vaux Alot]

Looks good this Count, the extent you go to is amazing to be fair. Don't think I'll be putting this much effort into the Chevette lol fair play to you though

Edit: If you can get your hand on an R28 from a v6 i'd replace the R25-R28, a lot stronger box. Using one on mine.

I know dude i was sold this one as being described as an r28 from a 3ltr v6 the to$$er! granted i didnt look at it before i handed over the cash anyway i wanted a R28.

Edit: what does yours say on the side? just R28?

[Count Vaux Alot]

J, where does the water rad go? Surely the IC has taken it's place...

It will go behind the intercooler mate :)

[gunny]

I saw a couple advertised as 28's that werent, makes you wobder if they're trying it on or its a genuine misunderstanding...

Yeh mine just says 'R28'

[leegsi1]

this is the best fabricating ive seen. great project :)

[Count Vaux Alot]

Got a little more done tonight after work

I needed some way of supporting the intercooler so I'm going to use some tube with some brackets on welded between the chassis (hopefully should add some strength too)

as so

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/DSCF7834.jpg

started with these

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000416.jpg

marked out the area of metal to be removed

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000418.jpg

in the mill

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000419.jpg

chomp

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000420.jpg

and cut to shape

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000422.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000423.jpg

so it fits here

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000424.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000425.jpg

the intercooler will sit on some rubbers on top of the brackets

both done ready to be welded in place

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000427.jpg

Next was the sump - more chopping to extend the capacity

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000428.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000429.jpg

one off cut of ali fit for the job

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000431.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000432.jpg

cut a chunk to size

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000433.jpg

[Count Vaux Alot]

then proceeded to beat it into shape to suite the sump

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000434.jpg

getting there

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000435.jpg

some more beating and the bend was complete

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000437.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000438.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000439.jpg

marked out the rough shape

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000440.jpg

began to cut that out

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000441.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000444.jpg

a little more detail

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000445.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000446.jpg

but no were near finished

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000447.jpg

the oil pick up needs modifying too

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000448.jpg

i think a 10-15mm reduction should be fine at this end and then add the same to the other end to keep the pick up at the bottom of the sump.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/P1000449.jpg

Night all

James

[staggy_gsi]

any more progress on this?!?!

[Nova_Tek]

Great fabrication work. Wish I had all them tools in the garage.

[Count Vaux Alot]

No progress on anything ATM unfortunately, normallity should resume shortly though :)

[Benn]

Guessing you can tig like a pro too then... Nice work on the sump.

[Count Vaux Alot]

Evening all, so all went quiet on this (along with all my tinkering with cars etc) due to a house move. Two months down the road and im trying to get back on track!

During the move I dumped the contents of my previous garage in the workshop prohibiting any movement let alone any work from getting done. Meaning the first job was a clear out.

I was faced with this to start.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/dd766e97.jpg

After a sort out, so I could actually get to the car.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/29f82b66.jpg

Bonnet off

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/50e13e03.jpg

The O/S front wing to be removed - what could be underneath I wonder?
http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/2fb83936.jpg

Heres a clue

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/fe4c27d3.jpg

Wing off

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/352b1f09.jpg

As expected some crust but nothing too serious

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/39d13618.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/b7e72179.jpg

A brief scrape about didn't reveal any more nasties thankfully just a pile of rust

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/dd61599e.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/e67b9b2b.jpg

This is the worst of it on this side

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/15a717d4.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/7d27b70f.jpg

At least know I know what I need to make and buy to get some progress going.

[paul080803]

Really looking forward to seeing some progress on this!! I will have to have a good look round it sometime :thumb:

[Benn]

Moved again? Have you bin out the nova project?

[Count Vaux Alot]

Yep moved again! Long story lol

What about the nova sorry?

[SimonTW]

Nice to see some progress on this one. Looking forward to seeing some on the Nova saloon soon hopefully too! :thumb:

[Benn]

What about the nova sorry?

Are you not doing it any more? As your back to the kadett.

[Count Vaux Alot]

It's still there Benn - I'm trying to sort some space to work on it.

[Count Vaux Alot]

Heres a couple of pics of the new engine to remind everyone what its looks like lol

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/187e22fd.jpg

Corsa vxr pistons and rods

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/430e975a.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/6ea6fd6d.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/47150638.jpg

[Benn]

Looking good dude, i still have these springs for you...

[The Simps]

Quite honestly - shocking progress! Nothing but excuses! lol

Hope you're well mate :thumb:

[MK999]

Quite honestly - shocking progress! Nothing but excuses! lol

Speaking of which when are we taking a grinder to your jap scrap?

Been about 18 months now lol

[Southie]

Really looking forward to this getting going again, never a boring moment on your builds James.

[Count Vaux Alot]

Progress people progress!

So some goodies arrived

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/504524f0.jpg

which lead to the removal of these

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/beed25b3.jpg

Before I got grinder happy I wanted to further inspection this suspect looking area were the paint meets the rust...

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/c7298624.jpg

After knocking back the many layers of paint and some filler with the DA I was pleasantly surprised not to find a complete rust fest underneath.

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/93e8654c.jpg

however this corner was worse than I had hoped

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/d6a8c300.jpg

time to clean things up a bit

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/0563a5dc.jpg

Holed!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/1598b520.jpg

Not so bad under the strengthening box not that it really makes much difference as there is rust all around it lol

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/f42dcefd.jpg

Stripped the whole under arch back to find exactly what was lurking

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/cc789903.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/5d586b76.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/aea4aebe.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/ce6b8a7a.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/96d50fb1.jpg

[Count Vaux Alot]

some time later out came the grinder to cut out some rot - thankfully there wasn't too much crust underneath

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/3a301a12.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/bcd11a26.jpg

spots drilled out down the A pillar/door jam

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/406279fd.jpg

Sliced a bit more out carefully does it

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/3bf8efba.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/2c605c86.jpg

leaving this

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/4ed660eb.jpg

not too bad either

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/c5c319ed.jpg

Wheeled her outside for a clean up inside

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/6c1a6609.jpg

she hasn't seen the outside for a while - looking a bit sorry

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/9cccfc3e.jpg

back on with the car I began to clean and sand all of the under arch, then stuck some rust killer on it

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/303486cf.jpg

I could now concentrate on this area

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/4e07b118.jpg

cut out the rot

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/94f1fea0.jpg

the beginnings of the repair section

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/221d96e0.jpg

bent welded and tweaked to fit

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/c44ce675.jpg

[Count Vaux Alot]

in position

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/1d7b3643.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/d2d409d5.jpg

ready to be welded

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/6dbbee76.jpg

Before I can make that permanent I needed to remove the rotten wing mount I was using for reference - I got brave and chopped it out

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/ec75c6f2.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/59f37d0b.jpg

All gone!

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/7e3b7b4b.jpg

http://i248.photobucket.com/albums/gg167/Count85/Kadett%20Saloon/7a21c1d7.jpg

more reconstruction needed next time ;D

[paul080803]

Awesome work as usuall!!!

[ben doodar]

Awesome work as always dude love the fabrication work.

[Vlietje]

Damn you have got some skills boy! Great build!

[Count Vaux Alot]

Thanks Guys :)