Rallycar reshell

[steg1970]

I originally bought my this Nova in 2000 of a lad local who if memory serves me well was getting banned for speeding so his car was up for sale. I parted with my £800 and became the owner of a G plate 1990 1.4SR, non-sunroof Nova. The intention was to compete in sprints and hillclimbs in the North of England Championship, mainly because my first love, rallying was out of reach financially. Within a couple of years my circumstances had changed with both myself and my wife getting a series of good promotions meaning that after two years of this championship, with little success, I was in a position to convert it to a rally car and compete in stage events.

After several years of rallying in the AS Performance North of England Rally Championship, with many class wins and championship class success it became obvious that the Nova had suffered one too many hard landings and was starting to show its age. After a third successive class win on the North West Stages in 2011 we found out my wife was expecting our first baby. It seemed like a good time to take the car off the road and re-shell it. I was already planning this as I had procured another shell, it just brought my plans forward.

http://i30.photobucket.com/albums/c319/stevo1970/LOZ_1087.jpg

How the old bus looks now, partially stripped.

http://i30.photobucket.com/albums/c319/stevo1970/Re-shell%20pics/IMG_0481.jpg

Here then is a pictorial record of the re-shell, I'll try to up date it regularly but with a new baby in the house progress is inevitably rather slow!!

Collecting the shell from Derby.

http://i30.photobucket.com/albums/c319/stevo1970/Re-shell%20pics/NewBodyShell006.jpg

Once home it was stripped and made ready for blasting.

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After stripping it was off to the local bead blasting outfit, the shell was then painted in a weldable primer.

http://i30.photobucket.com/albums/c319/stevo1970/Re-shell%20pics/IMG_0037.jpg

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On return it was obvious there was more work to do than I first suspected.

http://i30.photobucket.com/albums/c319/stevo1970/Re-shell%20pics/DSC00278.jpg

The shell was basically strong but it still required a lot of work, new floors had to be fabricated from steel sheet.

http://i30.photobucket.com/albums/c319/stevo1970/Re-shell%20pics/IMG_0057.jpg

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[Rickyb]

thats awsome i love the full new floors hope theres not to much welding todo.
rick

[calibra-keith]

looks like this could be an interesting thread, im wanting to blast mine soon (myself), any other plans other than just re shell ?

[nevidred]

i will be keeping an eye on this out of intrest what sort of money did the blasting and primer cost ???

[steg1970]

i will be keeping an eye on this out of intrest what sort of money did the blasting and primer cost ???

It cost £560 for the bead blast and paint.

[steg1970]

Sorry guys, thanks to failure in my external back up hard drive the rest of the bodywork pics have been lost, i'm gutted over this as it was a great record of the extensive repairs to the shell.

After the floors were replaced, both rear quarters were renewed, the headlight support panels and the floor cross brace were cut from the knackered shell and welded in to the new one.

I then rubbed it down and painted it in ford Diamond White (only because Jawel supply this at a much reduced cost over Vauxhall Polar White)

Following are the pics after it was painted and prepared for the assembly.

http://i30.photobucket.com/albums/c319/stevo1970/Re-shell%20pics/IMG_0473.jpg

[steg1970]

More pics.

With floor cross brace, seat rails and altered top mount for Corsa EPAS column.

http://i30.photobucket.com/albums/c319/stevo1970/Re-shell%20pics/IMG_0479.jpg

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[steg1970]

I've started putting the whole thing back together again.

The wiring loom was stripped of all unnecessary wires, like rear wiper, heated screen, etc, and others, like lamp pod and fuel pump, added in. It was all then wrapped with spiral band.

http://i30.photobucket.com/albums/c319/stevo1970/Re-shell%20pics/IMG_0550.jpg

The Corsa B EPAS column was mounted on modified brackets behind the dash. The fuse box was slightly modified to give clearance when mounted in the original position.

http://i30.photobucket.com/albums/c319/stevo1970/Re-shell%20pics/IMG_0554.jpg

http://i30.photobucket.com/albums/c319/stevo1970/Re-shell%20pics/IMG_0552.jpg

Due to the lack of a bulkhead the original blower fan and matrix could not be used therefore a new mini fan and matrix are to be used.

http://i30.photobucket.com/albums/c319/stevo1970/Re-shell%20pics/IMG_0555.jpg

This will be mounted under the dash, it will only provide a demist to the screen only, the molded plastic ducts have been cut and fitted with 2 inch flanges to join with new ducting from the fan via a Y piece.

http://i30.photobucket.com/albums/c319/stevo1970/Re-shell%20pics/IMG_0553.jpg

From under neath (including ugly bugger holding the camera)

http://i30.photobucket.com/albums/c319/stevo1970/Re-shell%20pics/IMG_0562.jpg

The ducting before it was fitted to the dash.

http://i30.photobucket.com/albums/c319/stevo1970/Re-shell%20pics/IMG_0564.jpg

[Iain]

You must be really pleased the shell looks fantastic

[rallycraig]

That's my old shell, good to see it getting a new lease of life.

[brainsnova]

Diamond white is nice but don't park next to a frozen white ford as it a lot nicer and brighter

[hotrod]

Looking good mate! Looks like you doing a good and proper job! :thumb:

[phunkynova]

That's looking sweet keep up the good work

[BROD]

Brilliant work mate, more pics! :P

[steg1970]

The rebuild is almost complete, after a bit of a false start we're aiming to do the SMC stages at Weeton as a shakedown.

Anyway there follows some pics of the nearly completed car. I'll take some more detail shots in the next week or so.

No advertising decal on yet, no MOT and the motor not set up.

http://i30.photobucket.com/albums/c319/stevo1970/Re-shell%20pics/IMG_1006.jpg

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[Iain]

That looks great, liking the gearbox access mod

[offplot]

Looking good steve - when are you hoping to be next out ?

[steg1970]

Looking good steve - when are you hoping to be next out ?

We were supposed to be out for the Jack Frost to shakedown for the North West Stages but we've had to delay until the SMC stages at Weeton for the debut. Had the car out for the first run up the road yesterday, needs set up properly so just pottered, I think both rear brake cylinders are seized so i'll chang them. Also not sure about the power steering, even on the lowest setting it feels too easy.

Have you still got the Astra? Did you get it going in the end? I've looked on a few entry lists but not seen your name.

[offplot]

The astra has gone steve - i had to cut my losses so i got rid - needed a new loom and some structial welding and after spending a couple of grand i felt like i was getting nowhere - shame really but hey ho.
Got a nova and a corsa c now - both forest cars - used the nova half a dozen times down the lanes and in the woods but now using the corsa as its cheaper to fix if i bin it - lol.
Will pop to weeton to say hi if you do the event - let me know.

[steg1970]

We did manage to get to Weeton for a shakedown, the new car was quick but several problems meant we had 3 stage maximums. First we had an oil problem which meant oil being chucked out of the breather, this turned out to be nothing more than over filled. Then a broken shaft required recovery back to service, odd timing as this shaft had done nearly 30 rallies in the previous shell without complaint and then finally a puncture on the last stage which looks to have damaged the steering too.

Good points, the Corsa EPAS was good, better feel than I expected, The Htdraulic handbrake improved throughout the day to a point where it actually became useful on the last 4 stages.

Not sure when we're next out.

Now some pics, the first couple are at home just after the MOT and the others on the event.

http://i30.photobucket.com/albums/c319/stevo1970/Nova%20Rally%20Pics/DSC_0054.jpg

http://i30.photobucket.com/albums/c319/stevo1970/Nova%20Rally%20Pics/DSC_0053.jpg

http://i30.photobucket.com/albums/c319/stevo1970/Nova%20Rally%20Pics/DSC_0055.jpg

http://i30.photobucket.com/albums/c319/stevo1970/Nova%20Rally%20Pics/418.jpg

http://i30.photobucket.com/albums/c319/stevo1970/Nova%20Rally%20Pics/678.jpg

[jimbob-mcgrew]

sweet ride. top job :)
lovin the mini matrix