Rob's Nova C20XE Project!

[RobC20LET]

Hi all, Im a member on Mig and had interest from one of your members so thought i'd copy my Project over onto here.. being as its a Nova


Welcome to my project thread, Im finally getting my finger out of my ass and in the process of building a super solid, reliable, daily driver/track car. and trying to make it look very similar to my first car being a Nova SRi..

History of the Nova..

It started its life as a rental vehicle but for some reason didnt do much more than 55k miles (obviously no one wanted to be seen in it) it had a reg change to hide the fact it was used as a rental yet it still has all its original windows and i even found the service book in its holder with the reg on the windows!! I did think i had bought a 'ringer' yet the chassis numbers the same and its all right on the v5 doc.

I bought it off eBay, It looked clean yet it was very cheap so i knew i was in for abit of a mission..
Drove from nottingham to nelson in lanc. which was like going into a different world! And when i first saw it, it was clear that the age really had taken its toll! It had been welded a few times and arches filled and the doors didnt have any bottoms! but i was happy to be in a Nova again, plus being a 1.2 it only cost me £10 to get home while my lift used £50 there and back!!

I started to use it for going to work for a while until i had a slight bump from an old dear which i took as a sign to crack on with it.. It needed a new front end anyway...

I hope you like pictures as i will be uploading as many as poss along the way..

Here is some to start off..

http://img32.imageshack.us/img32/479/novau.jpg (http://imageshack.us/photo/my-images/32/novau.jpg/)
Uploaded with ImageShack.us (http://imageshack.us/)

http://img442.imageshack.us/img442/2096/nova2k.jpg (http://imageshack.us/photo/my-images/442/nova2k.jpg/)
Uploaded with ImageShack.us (http://imageshack.us/)

http://img210.imageshack.us/img210/1663/nova3g.jpg (http://imageshack.us/photo/my-images/210/nova3g.jpg/)
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The aftermath!!

http://img338.imageshack.us/img338/9112/nova5f.jpg (http://imageshack.us/photo/my-images/338/nova5f.jpg/)
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http://img839.imageshack.us/img839/8638/nova6.jpg (http://imageshack.us/photo/my-images/839/nova6.jpg/)
Uploaded with ImageShack.us (http://imageshack.us/)



http://img846.imageshack.us/img846/850/nova7r.jpg (http://imageshack.us/photo/my-images/846/nova7r.jpg/)
Uploaded with ImageShack.us (http://imageshack.us/)

http://img267.imageshack.us/img267/4161/nova8.jpg (http://imageshack.us/photo/my-images/267/nova8.jpg/)
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http://img846.imageshack.us/img846/8096/nova11a.jpg (http://imageshack.us/photo/my-images/846/nova11a.jpg/)
Uploaded with ImageShack.us (http://imageshack.us/)

http://img193.imageshack.us/img193/8358/nova12v.jpg (http://imageshack.us/photo/my-images/193/nova12v.jpg/)
Uploaded with ImageShack.us (http://imageshack.us/)

http://img220.imageshack.us/img220/8048/nova13.jpg (http://imageshack.us/photo/my-images/220/nova13.jpg/)
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http://img846.imageshack.us/img846/2658/nova15p.jpg (http://imageshack.us/photo/my-images/846/nova15p.jpg/)
Uploaded with ImageShack.us (http://imageshack.us/)

http://img213.imageshack.us/img213/7567/nova16.jpg (http://imageshack.us/photo/my-images/213/nova16.jpg/)
Uploaded with ImageShack.us (http://imageshack.us/)

http://img171.imageshack.us/img171/4730/nova17.jpg (http://imageshack.us/photo/my-images/171/nova17.jpg/)
Uploaded with ImageShack.us (http://imageshack.us/)

http://img213.imageshack.us/img213/4789/nova19.jpg (http://api.viglink.com/api/click?format=go&drKey=1059&loc=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer.html&v=1&libid=1336477766385&out=http%3A%2F%2Fimageshack.us%2Fphoto%2Fmy-images%2F213%2Fnova19.jpg%2F&ref=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F&title=Nova%20C20XE%20daily%20RACER!&txt=%3CIMG%20border%3D0%20alt%3D%22%22%20src%3D%22 http%3A%2F%2Fimg213.imageshack.us%2Fimg213%2F4789% 2Fnova19.jpg%22%3E&jsonp=vglnk_jsonp_13364783219681)
Uploaded with ImageShack.us (http://imageshack.us/)


As you can see it isnt the cleanest Nova in the world.. BUT, It will be http://www.migweb.co.uk/forums/images/smilies/wink.gif

[RobC20LET]

Ive NEVER done this kind of thing before.. hence why my Corsa project fell through! But my hearts always been with Novas so it gave me the will power to learn! I tryed taking many photos to help anyone else in any way as i couldnt find much visual info on ripping a car to bits n welding it up

Well this is where my welding started, Took me a while to get used to the equipment as its not like the 3 phase i had a play with at work..

http://img94.imageshack.us/img94/8351/nova18.jpg (http://imageshack.us/photo/my-images/94/nova18.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

I fitted the chassis kit after welding the front slam panel..

http://img341.imageshack.us/img341/48/nova20.jpg (http://imageshack.us/photo/my-images/341/nova20.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img31.imageshack.us/img31/2226/nova21h.jpg (http://imageshack.us/photo/my-images/31/nova21h.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img641.imageshack.us/img641/3237/nova25.jpg (http://imageshack.us/photo/my-images/641/nova25.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

Stitch welded the whole front end..


http://img405.imageshack.us/img405/193/nova26k.jpg (http://imageshack.us/photo/my-images/405/nova26k.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img857.imageshack.us/img857/1588/nova27.jpg (http://imageshack.us/photo/my-images/857/nova27.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

I then cut off all the horrid bits of rot and crusty patches that had been welded on before, cleaned it up and made my own plates out of 2mm steel sheet.
Snap-on cutters worked very nice and was quite easy to shape up...

http://img696.imageshack.us/img696/7360/31009867.jpg (http://imageshack.us/photo/my-images/696/31009867.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img94.imageshack.us/img94/9792/51568943.jpg (http://imageshack.us/photo/my-images/94/51568943.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img171.imageshack.us/img171/703/nova24.jpg (http://imageshack.us/photo/my-images/171/nova24.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img825.imageshack.us/img825/9266/nova28.jpg (http://imageshack.us/photo/my-images/825/nova28.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

Then went on to finish off the inner arch panels.. ive made them slightly smaller than original (not as wide) but im going to make a mud flap to fill the gap between it and the wing.

http://img403.imageshack.us/img403/9576/nova29.jpg (http://imageshack.us/photo/my-images/403/nova29.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img401.imageshack.us/img401/8829/nova30y.jpg (http://imageshack.us/photo/my-images/401/nova30y.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

i slapped on some paint to stop it going bad again with this ****e weather we have..

http://img713.imageshack.us/img713/3561/nova31.jpg (http://imageshack.us/photo/my-images/713/nova31.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img220.imageshack.us/img220/6373/nova32.jpg (http://imageshack.us/photo/my-images/220/nova32.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img85.imageshack.us/img85/1220/nova33.jpg (http://api.viglink.com/api/click?format=go&drKey=1059&loc=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer.html&v=1&libid=1336477766385&out=http%3A%2F%2Fimageshack.us%2Fphoto%2Fmy-images%2F85%2Fnova33.jpg%2F&ref=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F&title=Nova%20C20XE%20daily%20RACER!&txt=%3CIMG%20border%3D0%20alt%3D%22%22%20src%3D%22 http%3A%2F%2Fimg85.imageshack.us%2Fimg85%2F1220%2F nova33.jpg%22%3E&jsonp=vglnk_jsonp_13364788092292)

[RobC20LET]

Things started to look good on the welding side.. and my first nova died by rolling on its roof so i thought it would be a good measure to buy a Harry Hockley roll cage!

http://img267.imageshack.us/img267/1738/nova35.jpg (http://imageshack.us/photo/my-images/267/nova35.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img802.imageshack.us/img802/8071/nova36.jpg (http://imageshack.us/photo/my-images/802/nova36.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img402.imageshack.us/img402/6218/nova37.jpg (http://imageshack.us/photo/my-images/402/nova37.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img191.imageshack.us/img191/1134/nova38.jpg (http://imageshack.us/photo/my-images/191/nova38.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img690.imageshack.us/img690/4862/nova40.jpg (http://imageshack.us/photo/my-images/690/nova40.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img707.imageshack.us/img707/2331/nova39.jpg (http://imageshack.us/photo/my-images/707/nova39.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

Do you think i need electric windows?

http://img405.imageshack.us/img405/5674/nova34.jpg (http://imageshack.us/photo/my-images/405/nova34.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img38.imageshack.us/img38/6502/nova41.jpg (http://imageshack.us/photo/my-images/38/nova41.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img256.imageshack.us/img256/4505/nova42.jpg (http://imageshack.us/photo/my-images/256/nova42.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img254.imageshack.us/img254/9441/nova43.jpg (http://imageshack.us/photo/my-images/254/nova43.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

Chassis leg mod for bigger engine

http://img259.imageshack.us/img259/2592/nova44.jpg (http://imageshack.us/photo/my-images/259/nova44.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

I did abit more welding at the front then went over it making sure i hadnt missed any where.. i still need to do abit to the bulkhead where the bars meet the strut mounts but overall the front is done.. so i started with the rear arches.. i didnt take pics of how i did it but i will tell you..

First i got the panels so i knew how big they were, then measured up how much rot was on the arches.. masking tapped the outside and drawn out the 'cutting line' then carefully as to not cut anything bar the outside skin i used a thin cutting disc n had it off!! i then cut the new panel down to size with around 15mm overlap from the cut edge, as the inner panel lip was rotton too i cut it off.. then cut the lip on the new panel in various places and folded it up and when fitting slid the inner panel between it to give me good metal to weld onto and most of all.. a ROLLED ARCH!!

Its not yet welded underneath as its too cold for me to go and play but here is the outside done..

http://img834.imageshack.us/img834/6818/nova49.jpg (http://imageshack.us/photo/my-images/834/nova49.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img443.imageshack.us/img443/4149/nova48m.jpg (http://imageshack.us/photo/my-images/443/nova48m.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

http://img521.imageshack.us/img521/5567/nova47.jpg (http://api.viglink.com/api/click?format=go&drKey=1059&loc=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer.html&v=1&libid=1336477766385&out=http%3A%2F%2Fimageshack.us%2Fphoto%2Fmy-images%2F521%2Fnova47.jpg%2F&ref=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F&title=Nova%20C20XE%20daily%20RACER!&txt=%3CIMG%20border%3D0%20alt%3D%22%22%20src%3D%22 http%3A%2F%2Fimg521.imageshack.us%2Fimg521%2F5567% 2Fnova47.jpg%22%3E&jsonp=vglnk_jsonp_13364789055083)

[RobC20LET]

http://img545.imageshack.us/img545/7758/nova50.jpg (http://imageshack.us/photo/my-images/545/nova50.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

Like i said its not done underneath and i know its not straight.. yet! but heres an under view

http://img545.imageshack.us/img545/3757/nova45.jpg (http://imageshack.us/photo/my-images/545/nova45.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

WORD OF WARNING.. your car is full of sealant on all joints and big lumps in places you can not see.. while doing the sill laying down i didnt see that the car was on fire http://www.migweb.co.uk/forums/images/smilies/lmao.gif heres a pic of the sut left on the windscreen..

http://img29.imageshack.us/img29/5570/nova51.jpg (http://imageshack.us/photo/my-images/29/nova51.jpg/)

Uploaded with ImageShack.us (http://imageshack.us/)

I do have ALOT of goodies for the car already but all will be revealed once there being fitted..
But for now as the weather isnt too good to be welding outside ive turned my attention to the engine (which is in my nice warm garage) and here are some little treats that im sure most people will like http://www.migweb.co.uk/forums/images/smilies/thumb.gif

http://img576.imageshack.us/img576/3690/nova53.jpg (http://api.viglink.com/api/click?format=go&drKey=1059&loc=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer.html&v=1&libid=1336477766385&out=http%3A%2F%2Fimageshack.us%2Fphoto%2Fmy-images%2F576%2Fnova53.jpg%2F&ref=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F&title=Nova%20C20XE%20daily%20RACER!&txt=%3CIMG%20border%3D0%20alt%3D%22%22%20src%3D%22 http%3A%2F%2Fimg576.imageshack.us%2Fimg576%2F3690% 2Fnova53.jpg%22%3E&jsonp=vglnk_jsonp_13364789694174)

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My block is away getting rebored but once back ill put up a few pics of it going together.

Rob.

[RobC20LET]

Cleaned up underneath and finished welding it up, then slapped on the last bit of filler i had..

http://img687.imageshack.us/img687/9888/nova54.jpg (http://imageshack.us/photo/my-images/687/nova54.jpg/)


http://img39.imageshack.us/img39/3566/nova55.jpg (http://imageshack.us/photo/my-images/39/nova55.jpg/)


http://img835.imageshack.us/img835/4580/nova56.jpg (http://imageshack.us/photo/my-images/835/nova56.jpg/)

Im going to get some more filler tomorrow and also treat myself to a palm sander, but overall im very happy with finishing off the arch and was the hardest part ive done so far (as you can see it,and me being abit of a perfectionist/fussy tw@ http://www.migweb.co.uk/forums/images/smilies/lmao.gif )

I now only have two more rotten bits left before i have a completely solid Nova!!!

http://img717.imageshack.us/img717/6585/nova57.jpg (http://imageshack.us/photo/my-images/717/nova57.jpg/)


http://img818.imageshack.us/img818/5602/nova58.jpg (http://imageshack.us/photo/my-images/818/nova58.jpg/)


http://img831.imageshack.us/img831/2996/nova59.jpg (http://imageshack.us/photo/my-images/831/nova59.jpg/)


Ohhh wait.. Four more rotten bits, I need new DOORS!! http://www.migweb.co.uk/forums/images/smilies/smile.gif

http://img684.imageshack.us/img684/4002/nova60.jpg (http://imageshack.us/photo/my-images/684/nova60.jpg/)


I hear its going to be nice tomorrow too so hopefully i can get the other arch and rear end done and start fitting nice little treats like these...

http://img593.imageshack.us/img593/3731/nova61.jpg (http://imageshack.us/photo/my-images/593/nova61.jpg/)


http://img845.imageshack.us/img845/2393/nova62.jpg (http://imageshack.us/photo/my-images/845/nova62.jpg/)

http://img715.imageshack.us/img715/5702/nova63.jpg (http://api.viglink.com/api/click?format=go&drKey=1059&loc=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer.html&v=1&libid=1336477766385&out=http%3A%2F%2Fimageshack.us%2Fphoto%2Fmy-images%2F715%2Fnova63.jpg%2F&ref=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F&title=Nova%20C20XE%20daily%20RACER!&txt=%3CIMG%20border%3D0%20alt%3D%22%22%20src%3D%22 http%3A%2F%2Fimg715.imageshack.us%2Fimg715%2F5702% 2Fnova63.jpg%22%3E&jsonp=vglnk_jsonp_13364790532625)

[RobC20LET]

Working hard lastnight in the dark i managed to get the n/s arch and rear slam panel welded up..

http://img826.imageshack.us/img826/9215/img2063fe.jpg (http://imageshack.us/photo/my-images/826/img2063fe.jpg/)


http://img821.imageshack.us/img821/2168/img2062od.jpg (http://api.viglink.com/api/click?format=go&drKey=1059&loc=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer.html&v=1&libid=1336477766385&out=http%3A%2F%2Fimageshack.us%2Fphoto%2Fmy-images%2F821%2Fimg2062od.jpg%2F&ref=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F&title=Nova%20C20XE%20daily%20RACER!&txt=%3CIMG%20border%3D0%20alt%3D%22%22%20src%3D%22 http%3A%2F%2Fimg821.imageshack.us%2Fimg821%2F2168% 2Fimg2062od.jpg%22%3E&jsonp=vglnk_jsonp_13364791253736)


when its dry im going to go over the rear end looking for anymore rust but hopefully will be prepping and painting / undersealing the whole underneath over the weekend!!


Been working on the car for 8 hours straight today.. Ive finally welded up all the crusty bits i kept finding so started prepping the shell for painting and undersealing

Here are a few pics..

http://img862.imageshack.us/img862/9049/img2073s.jpg (http://api.viglink.com/api/click?format=go&drKey=1059&loc=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer.html&v=1&libid=1336477766385&out=http%3A%2F%2Fimageshack.us%2Fphoto%2Fmy-images%2F862%2Fimg2073s.jpg%2F&ref=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F&title=Nova%20C20XE%20daily%20RACER!&txt=%3CIMG%20border%3D0%20alt%3D%22%22%20src%3D%22 http%3A%2F%2Fimg862.imageshack.us%2Fimg862%2F9049% 2Fimg2073s.jpg%22%3E&jsonp=vglnk_jsonp_13364791777507)

http://img638.imageshack.us/img638/5585/img2074t.jpg (http://imageshack.us/photo/my-images/638/img2074t.jpg/)

The holes in the wheel well were abit rotton so i plated them up, as im not having carpets etc would you recommend i weld the rest up too like this?

http://img41.imageshack.us/img41/2580/img2072ey.jpg (http://imageshack.us/photo/my-images/41/img2072ey.jpg/)

Also removing all the old underseal is taking forever so i had a break and tried out the paint ive got for my roll cage, axle and lower arms..

http://img705.imageshack.us/img705/1635/img2075f.jpg (http://imageshack.us/photo/my-images/705/img2075f.jpg/)

http://img10.imageshack.us/img10/2036/img2078il.jpg (http://imageshack.us/photo/my-images/10/img2078il.jpg/)

It was done with a thin layer of white primer and then the orange but gives an idea of what it will look like.. What do you think?

[RobC20LET]

Just a little update.. I hadnt done ANYTHING until today! after the 8 hours of laying on my back getting covered in crap taking the underseal off, it really put me off from carrying out the task yet i wouldnt let myself just paint over it doing half a job.

So i made myself another little project and have been taking some time doing so, with a big help from my polish friend Rafal who literally came and picked the car up high enough for me to fit.. i now have my car sat on a jig/spit!

http://img189.imageshack.us/img189/192/img2150pw.jpg (http://imageshack.us/photo/my-images/189/img2150pw.jpg/)

http://img856.imageshack.us/img856/4461/img2151et.jpg (http://imageshack.us/photo/my-images/856/img2151et.jpg/)

http://img593.imageshack.us/img593/6306/img2152c.jpg (http://imageshack.us/photo/my-images/593/img2152c.jpg/)

So after only a couple of hours (as its started to rain) i have taken off twice the amount i did in the 8 hours laid on the ground!
It only needs one hand to spin the car with a locking pin to hold it in place, heres where ive got up to..

http://img829.imageshack.us/img829/7656/img2148g.jpg (http://imageshack.us/photo/my-images/829/img2148g.jpg/)

http://img62.imageshack.us/img62/8631/img2149ad.jpg (http://api.viglink.com/api/click?format=go&drKey=1059&loc=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer-2.html&v=1&libid=1336479226775&out=http%3A%2F%2Fimageshack.us%2Fphoto%2Fmy-images%2F62%2Fimg2149ad.jpg%2F&ref=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer.html&title=Nova%20C20XE%20daily%20RACER!&txt=%3CIMG%20border%3D0%20alt%3D%22%22%20src%3D%22 http%3A%2F%2Fimg62.imageshack.us%2Fimg62%2F8631%2F img2149ad.jpg%22%3E&jsonp=vglnk_jsonp_13364792508471)

This has made my life so much easier and the car might actually get done some time this year now!

Did some more work today, underneath is almost underseal free.. just some awkward places to work on.

http://img651.imageshack.us/img651/6814/img2169cb.jpg (http://imageshack.us/photo/my-images/651/img2169cb.jpg/)

http://img831.imageshack.us/img831/510/img2167if.jpg (http://imageshack.us/photo/my-images/831/img2167if.jpg/)

http://img843.imageshack.us/img843/7104/img2168l.jpg (http://imageshack.us/photo/my-images/843/img2168l.jpg/)

Then my hands started feeling abit numb from all the grinding/wire wheeling so decided to get on with something else..

http://img267.imageshack.us/img267/4260/img2161qs.jpg (http://imageshack.us/photo/my-images/267/img2161qs.jpg/)

http://img823.imageshack.us/img823/7213/img2162b.jpg (http://imageshack.us/photo/my-images/823/img2162b.jpg/)

http://img718.imageshack.us/img718/5999/img2166sd.jpg (http://api.viglink.com/api/click?format=go&drKey=1059&loc=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer-2.html&v=1&libid=1336479226775&out=http%3A%2F%2Fimageshack.us%2Fphoto%2Fmy-images%2F718%2Fimg2166sd.jpg%2F&ref=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer.html&title=Nova%20C20XE%20daily%20RACER!&txt=%3CIMG%20border%3D0%20alt%3D%22%22%20src%3D%22 http%3A%2F%2Fimg718.imageshack.us%2Fimg718%2F5999% 2Fimg2166sd.jpg%22%3E&jsonp=vglnk_jsonp_13364792849532)

[RobC20LET]

Just a little update as i did abit of work on monday, with the welder in need of some bits i decided to start on something else instead of just sitting around waiting on the shops to open so i stripped my rear axle down and cleaned up ready for painting..
I also saw another thread people saying that to replace bushes the easiest way is to burn them out lol but other being toxic to breathe it must be messy too! so i thought i'd show how i replace them which took less than 5mins to do!

So here is what i started with..
http://img688.imageshack.us/img688/1186/img2170qj.jpg (http://imageshack.us/photo/my-images/688/img2170qj.jpg/)



I then use a metal saw and cut down the gap between the axle and bush all the way around then pull it off with some grips

http://img855.imageshack.us/img855/5480/img2171fn.jpg (http://imageshack.us/photo/my-images/855/img2171fn.jpg/)

Then i use a hammer to strike out the bush, being careful not to hit the axle and burring up the end.. you could always use a drift or socket to avoid this problem.

After five mins they are all out, to put new ones in i cheat and cut the new bush in half in the middle as trying to do them complete almost always rips the end off. yet polybushes come in halves anyway.

http://img19.imageshack.us/img19/8056/img2172bv.jpg (http://imageshack.us/photo/my-images/19/img2172bv.jpg/)

I then got to cleaning them up.. as you may have noticed i kind of get carried away..

http://img24.imageshack.us/img24/2241/img2174pq.jpg (http://imageshack.us/photo/my-images/24/img2174pq.jpg/)


I shall be getting some bits for my welder and paints for axle today.

But lots of goodies arrived for the engine today WOOHOO!

http://img822.imageshack.us/img822/6816/img2175ea.jpg (http://imageshack.us/photo/my-images/822/img2175ea.jpg/)

http://img525.imageshack.us/img525/7859/img2176s.jpg (http://imageshack.us/photo/my-images/525/img2176s.jpg/)

So i now have ARP bolts for mains, rods, head studs and flywheel. glyco bearings for mains and big ends, cometic head gasket and waisted valves at standard size. all to go with my semi slipper pistons and h-beam rods.

Im going to port and polish the head myself before getting the new guides fitted.

All i need to get for the engine now is..

Piper fast road cams double valve springs and vernier pulleys, Qed 45 direct to head throttle bodies and management kit, oil pump, water pump, cam belt kit and a decent exhaust manifold and system.

[RobC20LET]

Right.. Mission of the weekend was to get the shell fully welded up completely, no more messing! Results = Fully welded including grinding back some of my first welds and redoing them, removed the rest of underseal and cleaned up.
Reseal all panel joints with wurths silicone before priming all underside... then undersealed!

http://img11.imageshack.us/img11/628/img2179gq.jpg (http://imageshack.us/photo/my-images/11/img2179gq.jpg/)

http://img854.imageshack.us/img854/2052/img2180t.jpg (http://imageshack.us/photo/my-images/854/img2180t.jpg/)

http://img138.imageshack.us/img138/5507/img2183h.jpg (http://imageshack.us/photo/my-images/138/img2183h.jpg/)

http://img19.imageshack.us/img19/8823/img2184zy.jpg (http://imageshack.us/photo/my-images/19/img2184zy.jpg/)

http://img638.imageshack.us/img638/9749/img2181pb.jpg (http://imageshack.us/photo/my-images/638/img2181pb.jpg/)

http://img809.imageshack.us/img809/3808/img2182u.jpg (http://api.viglink.com/api/click?format=go&drKey=1059&loc=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer-2.html&v=1&libid=1336479226775&out=http%3A%2F%2Fimageshack.us%2Fphoto%2Fmy-images%2F809%2Fimg2182u.jpg%2F&ref=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer.html&title=Nova%20C20XE%20daily%20RACER!&txt=%3CIMG%20border%3D0%20alt%3D%22%22%20src%3D%22 http%3A%2F%2Fimg809.imageshack.us%2Fimg809%2F3808% 2Fimg2182u.jpg%22%3E&jsonp=vglnk_jsonp_13364793957183)

I managed to put two coats of paint on today before running out, i also blasted waxoil into all the internal parts of chassis.

http://img201.imageshack.us/img201/1063/img2186hi.jpg (http://api.viglink.com/api/click?format=go&drKey=1059&loc=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer-2.html&v=1&libid=1336479226775&out=http%3A%2F%2Fimageshack.us%2Fphoto%2Fmy-images%2F201%2Fimg2186hi.jpg%2F&ref=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer.html&title=Nova%20C20XE%20daily%20RACER!&txt=%3CIMG%20border%3D0%20alt%3D%22%22%20src%3D%22 http%3A%2F%2Fimg201.imageshack.us%2Fimg201%2F1063% 2Fimg2186hi.jpg%22%3E&jsonp=vglnk_jsonp_13364794313014)

[RobC20LET]

Time for a little update as havent been able to do anything until last night. Ive spent the week removing and rebuilding a dxi11 Renault engine out of two scrap engines lol and on saturday it was running with no problems.. So i thought as im in the swing of things ill start putting my engine together.

So as i had it bored out .5mm i spent two hours degreasing and steam cleaning the block, crank and all oil ways out to get rid of all swarf then lubed it up abit before fitting the new shells..

http://img24.imageshack.us/img24/1669/img2205jd.jpg (http://imageshack.us/photo/my-images/24/img2205jd.jpg/)

Then fitted the ARP mains studs with loctite, dropped the crank in and fitted the caps. lubed threads with ultra-torque grease fitted and torqued nuts 20..40..and 60 lb/ft as recommended (which felt very odd for me as i usually get a sweat on torquing up stuff i work on lol)

http://img155.imageshack.us/img155/3274/img2206wz.jpg (http://imageshack.us/photo/my-images/155/img2206wz.jpg/)

http://img204.imageshack.us/img204/319/img2207jj.jpg (http://imageshack.us/photo/my-images/204/img2207jj.jpg/)

I then fitted the pistons to the rods then fitted rings which IMO was the hardest part

http://img593.imageshack.us/img593/3476/img2213fm.jpg (http://imageshack.us/photo/my-images/593/img2213fm.jpg/)

Then compressed the rings and fitted pistons.. fitted big end bearings, connected rods, lubed up ARP bolts and torqued up to 55lb/ft

http://img839.imageshack.us/img839/7607/img2215xt.jpg (http://imageshack.us/photo/my-images/839/img2215xt.jpg/)

http://img829.imageshack.us/img829/8786/img2216n.jpg (http://imageshack.us/photo/my-images/829/img2216n.jpg/)

http://img839.imageshack.us/img839/4632/img2218wh.jpg (http://imageshack.us/photo/my-images/839/img2218wh.jpg/)

I was then shocked to see how much these pistons stick out at TBC!!!!

http://img689.imageshack.us/img689/83/img2219t.jpg (http://imageshack.us/photo/my-images/689/img2219t.jpg/)

Then i oiled up everything like crazy, stuck the bottom end in lined box and put it to sleep until the head is ready.

http://img840.imageshack.us/img840/4668/img2221w.jpg (http://api.viglink.com/api/click?format=go&drKey=1059&loc=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer-2.html&v=1&libid=1336479226775&out=http%3A%2F%2Fimageshack.us%2Fphoto%2Fmy-images%2F840%2Fimg2221w.jpg%2F&ref=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer.html&title=Nova%20C20XE%20daily%20RACER!&txt=%3CIMG%20border%3D0%20alt%3D%22%22%20src%3D%22 http%3A%2F%2Fimg840.imageshack.us%2Fimg840%2F4668% 2Fimg2221w.jpg%22%3E&jsonp=vglnk_jsonp_13364795031675)

[swedge]

good stuff for saving a rotter :) looking very good though

bet your neighbours lovede the sound of the wire wheel on the grinder going for hours lol

[RobC20LET]

So this is where i am up to with the project, i built up the bottom end sunday and worked on the head monday.


I keep looking at the bank balance then looking at TB's quite regular lol so to give me motivation ive set my self the task that i cant buy anything else until ive fully built the engine.

I'm not going mental yet im sure what i am doing will be an improvement.. but please feel free to give your opinion.

STD exhaust port.

http://img51.imageshack.us/img51/8869/img2238xq.jpg (http://imageshack.us/photo/my-images/51/img2238xq.jpg/)

http://img88.imageshack.us/img88/5975/img2239tc.jpg (http://imageshack.us/photo/my-images/88/img2239tc.jpg/)

Then i got the dremell out.. OH NOOO!

http://img443.imageshack.us/img443/1338/img2231g.jpg (http://imageshack.us/photo/my-images/443/img2231g.jpg/)

I then drawn out the exess and matched to the gasket

http://img713.imageshack.us/img713/4657/img2232e.jpg (http://imageshack.us/photo/my-images/713/img2232e.jpg/)

http://img685.imageshack.us/img685/6689/img2233c.jpg (http://imageshack.us/photo/my-images/685/img2233c.jpg/)

http://img406.imageshack.us/img406/5605/img2234si.jpg (http://imageshack.us/photo/my-images/406/img2234si.jpg/)

http://img190.imageshack.us/img190/4935/img2235k.jpg (http://imageshack.us/photo/my-images/190/img2235k.jpg/)

http://img857.imageshack.us/img857/5207/img2237w.jpg (http://imageshack.us/photo/my-images/857/img2237w.jpg/)

I'm far from finished.. im not going to be taking any more out just going to smooth it all completely now (which i havent even started at the enterace of the valve as im putting it off lol) then i sized up the inlet gasket to its ports which was next to no diffrence so im just going to smooth that all out and polish it up.

here is the before and after measurements..

http://img341.imageshack.us/img341/3373/img2241m.jpg (http://imageshack.us/photo/my-images/341/img2241m.jpg/)

http://img526.imageshack.us/img526/5984/img2242b.jpg (http://api.viglink.com/api/click?format=go&drKey=1059&loc=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer-3.html&v=1&libid=1336479516359&out=http%3A%2F%2Fimageshack.us%2Fphoto%2Fmy-images%2F526%2Fimg2242b.jpg%2F&ref=http%3A%2F%2Fwww.migweb.co.uk%2Fforums%2Fproje cts-restorations%2F492182-nova-c20xe-daily-racer-2.html&title=Nova%20C20XE%20daily%20RACER!&txt=%3CIMG%20border%3D0%20alt%3D%22%22%20src%3D%22 http%3A%2F%2Fimg526.imageshack.us%2Fimg526%2F5984% 2Fimg2242b.jpg%22%3E&jsonp=vglnk_jsonp_13364796411071)

Thanks for looking.. i will keep this upto date as i go along.

Rob

[RobC20LET]

good stuff for saving a rotter :) looking very good though

bet your neighbours lovede the sound of the wire wheel on the grinder going for hours lol

Haha thanks, im sure they love me very much :)

I thought it would be best to buy one in this condition and re do it all rather than splash out alot of cash on a solid one and rip it to bits anyway lol

[swedge]

aye thats the way, i see what your saying about putting off the headwork under the valve seats

bit of a **** to get into without hitting the valve seat, im building an xe and doing some diy headwork atm some pics on my project thread too

[Rickyb]

i like this project and +rep for saving the rotter. in rust we trust.

[SimonTW]

Great project thread! Fair play for getting so heavily stuck into it on your driveway!

[swedge]

Driveways are garages for the hardcore my drive is stones a is sore as hell when lying on it for a while

[Archie]

Cracking build so far, will be keeping an eye on it.

I just wish i could weld :(

+Rep :)

[Balley]

Well done on saving a rotter, similar state to mine. I see you live in Nottingham, my Mrs lives there so we will have to meet up when there done!

[nova ian]

Great stuff as said on MIG Rob. Love it :)

Glad to see you made it over here. Cracking Nova, can't wait to see it progress

Cheers
Ian

[RobC20LET]

Thanks for the interest guys, once done ill defo be up for meeting fellow Nova enthusiasts.

Spent 9 hours on the car today doing various bits and bobs, first off i put the last (3rd) coat on underneath and started doing the engine bay.. while it was drying i cut up my dash to get it to fit. Put another layer on the bay then took the rest of the sticky stuff off from inside and the roof, then marked up the side skirts and drilled holes to mount them up before it got dark.. as well as having to sort my sisters car out on a suprise visit (alt. belt coming off crank pully and squealing) yet on doing so finding lots of other bits reqd for its mot next month lol bloody peugeot's!

heres the pics of the day.

http://img88.imageshack.us/img88/3862/img2254op.jpg (http://imageshack.us/photo/my-images/88/img2254op.jpg/)

http://img269.imageshack.us/img269/9234/img2253eb.jpg (http://imageshack.us/photo/my-images/269/img2253eb.jpg/)

http://img842.imageshack.us/img842/7152/img2247z.jpg (http://imageshack.us/photo/my-images/842/img2247z.jpg/)

http://img585.imageshack.us/img585/110/img2248ta.jpg (http://imageshack.us/photo/my-images/585/img2248ta.jpg/)

http://img542.imageshack.us/img542/1889/img2249n.jpg (http://imageshack.us/photo/my-images/542/img2249n.jpg/)

http://img20.imageshack.us/img20/4185/img2250p.jpg (http://imageshack.us/photo/my-images/20/img2250p.jpg/)

http://img706.imageshack.us/img706/1698/img2251su.jpg (http://imageshack.us/photo/my-images/706/img2251su.jpg/)

http://img819.imageshack.us/img819/2451/img2255x.jpg (http://imageshack.us/photo/my-images/819/img2255x.jpg/)

I am however unhappy with the tatty dash with gaps in it etc.. so im planning on making some carbon end cappings to wrap around the roll cage holes and another panel to hold some guages. but tomorrow im going to finish off the painting outside and axle/lower arms, and prep the cage for painting!

Rob.

[Tiger13]

Thats looking great mate, Keep it up and your gonna have a real minter :-)

[Connor]

Some awesome work going into this build. Engine goodies look good :p
Will be keeping an eye on this one :thumb:

[RobC20LET]

Just a small update from yesterday, touched up the underside and engine bay prepped the cage for paint then painted the rear beam A.R.B and tank :)

http://img403.imageshack.us/img403/680/img2256m.jpg (http://imageshack.us/photo/my-images/403/img2256m.jpg/)

http://img825.imageshack.us/img825/7118/img2259n.jpg (http://imageshack.us/photo/my-images/825/img2259n.jpg/)

Just got to get some new hand brake cables and brake pipes to route in before i drop it back on its wheels!!

Feel like im actually getting somewhere lol

[Iain]

They look nuts, nice work! Should be very bright when its all built up.

Wish I'd had that spit when I was building mine, looks loads easier than rolling it onto its side.

[RobC20LET]

Haha TBH i dont think i could bring myself to roll mine on its side :)

Well ive finished painting underneath and am moving on to the inside which i needed it back on the ground, so that was the mission of the day!

I have fitted the polybushes etc then fitted the wishbones, beam and tank to the car..

http://img196.imageshack.us/img196/3069/img2261uu.jpg (http://imageshack.us/photo/my-images/196/img2261uu.jpg/)

http://img338.imageshack.us/img338/8073/img2262l.jpg (http://imageshack.us/photo/my-images/338/img2262l.jpg/)

Then took me ages to get it back on the ground.. it was 1m high and i only have a small jack, so the wheels came out!

http://img853.imageshack.us/img853/4557/img2263co.jpg (http://imageshack.us/photo/my-images/853/img2263co.jpg/)

http://img259.imageshack.us/img259/6656/img2265g.jpg (http://imageshack.us/photo/my-images/259/img2265g.jpg/)

Then i started cleaning up the inside and ended up cutting my finger quite bad lol so i called it a day!

Rob.

[Iain]

Haha the underside looks nuts, proper bright, love it!

Flocked dash might look nice :)

[RobC20LET]

Im not sure if im down with this flocked look, id like to see something in the flesh before i decide i dont like it though :)

[Iain]

You can have a touch of mine if you want.

[RobC20LET]

Ive just had a flick through your build and your dash actually looks awesome!

I want to make some molds from around the holes and cage to make some carbon end caps then id be real interested in getting it flocked!

You sould come down at the weekend mate, if you can tell where i live from the pics :)

[Iain]

So if I can't tell I don't get to come round? lol PM me if you want :)

[jafanan]

i like the yellow as its different but if it was me i would have done them black, as after a few months on the road the yellow will be grubby

keep the good work up though

[Nova-nation]

Looks good! Nice cage!

[RobC20LET]

Been doing a little bit more to this as i now have more time on my hands..

Got the rear axle all built back up now and brake pipes running through the car.

http://img210.imageshack.us/img210/4782/nova9999.jpg (http://imageshack.us/photo/my-images/210/nova9999.jpg/)

http://img694.imageshack.us/img694/548/nova999.jpg (http://imageshack.us/photo/my-images/694/nova999.jpg/)

http://img41.imageshack.us/img41/8599/nova99999.jpg (http://imageshack.us/photo/my-images/41/nova99999.jpg/)

Then i went and bought my QED throttle bodies so dropped on my spare head to see what it looks like as my other head is having the valve guides replaced.

http://img62.imageshack.us/img62/2082/img0196vot.jpg (http://imageshack.us/photo/my-images/62/img0196vot.jpg/)

http://img593.imageshack.us/img593/4863/img0198bx.jpg (http://imageshack.us/photo/my-images/593/img0198bx.jpg/)

http://img12.imageshack.us/img12/6523/img0199jk.jpg (http://imageshack.us/photo/my-images/12/img0199jk.jpg/)

I have also fitted a Quaife lsd to my f20 box

http://img513.imageshack.us/img513/8616/img0208ld.jpg (http://imageshack.us/photo/my-images/513/img0208ld.jpg/)

http://img829.imageshack.us/img829/5058/img2405xw.jpg (http://imageshack.us/photo/my-images/829/img2405xw.jpg/)

http://img507.imageshack.us/img507/3274/img0205f.jpg (http://imageshack.us/photo/my-images/507/img0205f.jpg/)

http://img801.imageshack.us/img801/4527/img0206fu.jpg (http://imageshack.us/photo/my-images/801/img0206fu.jpg/)

[Novaloony]

Very tidy project! ive just completely re wired my GTE rep and i thought that was bad! Very clean nova! +Rep!