Bored Bazil Buys Blue Bodyshell got Big Block Build

[bazil]

So talking to my dad one day I foolishly said I have to much stuff lying around and could do with a shell to put it all in, two days later he tells me he bought me a shell :wall:
So might aswell use the XE I've had lying for 7 years lol

Picked the shell up which need a little TLC but is strong in all the required places,
Unfortunatly it came up on a hpi check as being written off, scrapped and stolen :eek:
( maybe should have checked that out as I didn't get a log book with it either :tard: )

So over the last 3 weeks I've got it all sorted out, no longer registered as stolen, I can apply for a log book after a vic check and the issuance company have removed the theft marker from it too, good times.

I have a rough plan of what I want it to end up like but it's nothing to fancy,

http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/EBDAD5ED-DD98-4758-81AA-9DCE276B8C6A-15984-00001D4B0DC1D761_zpse2dac459.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/5a2344a3.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/6b7524c2.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/9310db25.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/d30bff25.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/2fa08aa1.jpg


That's as far as I got as the head has 8 bent exhaust valves and 2 damaged valve guides so I need to spend some cash on it, cash is tight just now so it can wait.

[millworm]

can't wait to see what this turns out like

[Balley]

Oh will this one actually get done!

[Edd]

Shouldn't you be starting work on the silver GSI really? lol

[Count Vaux Alot]

lol another one! Your as bad as me.

[bazil]

Oh will this one actually get done!

It has untill July, if I've not done anything by Billing it's getting binned lol


can't wait to see what this turns out like

Neither can I :)


Shouldn't you be starting work on the silver GSI really? lol

Pffft where the fun in that !
lol, this will give me a bit if practice, I've not really done any panel work in over 10 years!

Just basic stuff on this, back panel, rear arches, battery tray some seam welding and a bit of strengthening.
I have a fair amount of stuff I need shifted but can't be arsed selling it so its going to get used on this.

[bazil]

lol another one! Your as bad as me.

That's me upto 5 novas, my S3 my combo and a Vectra GSI I need to fix for the wife lol

[Count Vaux Alot]

were have your/are you going to source the back panel from?

[bazil]

I already have 2 in stock :) one for the silver gsi and one for the GTE so I will need to buy another one later,

[Spudly]

Lmfao @ having the panels 'in stock' lol


Hope you do crack on with it mate :thumb:

[sport]

You not finished this yet mate lol

[Edd]

I'll check back in 2017, probably be 25 pages of chat and still no actual work done lol

[bazil]

Lmfao @ having the panels 'in stock' lol


Hope you do crack on with it mate :thumb:

lol to much stock tbh, I want to use a lot of the stuff before it gets wasted,
I always fancied a REDTOP YOOOOOO but never got round to it,


You not finished this yet mate lol

Don't you start lol or I'll get dougie to work on it and delay yours even more :-D


I'll check back in 2017, probably be 25 pages of chat and still no actual work done lol

This thread is different mate, unlike the silver one which I just took to bits there is nothing I can take off this one, adding bits is the only way forward lol

[brainsnova]

Tbh when I first seen the shell and the surroundings I thought you were weighing it in lol

[Benn]

hahaha love your dad got you this to "put up or shut up"...

[NOV4_SPORT]

Yah Bazil has started another build thread ! Will be a good use of some of your parts and panels mate and like your saying will give you a car to practice your skills on again so will be a master for when it comes to the Gte and gsi !

Subscribed !

[bazil]

Jack of all trades and a master of none lol

Cheers Ian, ordered a pair of arch repair sections today and get them tomorrow, I'm having trouble finding some 1.5mm steel sheet, any idea of suppliers mate?

[bazil]

£36 from local motor factors, I was shocked that I got nova parts so easily lol

http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/E397262B-272F-4B8A-A66E-CFCB9A8CF5D3-18647-0000206FEF977E2B_zpse3a8cf94.jpg

I'm not oncall this weekend so I quite fancy getting the grinder out :)

[DAFTJOHN]

Do it do it do it.

[bazil]

Your going to hold this build up, it's all your fault John lol

Need that jig of yours :-D

[brainsnova]

You'll need kev's jogler

[bazil]

I've got one mate, :)

[brainsnova]

The arches didn't look that bad so the repair should be straight forward

[bazil]

Looks can be deceiving lol, I want to modify the inner arch anyway for better tyre clearance plus I shall roll the repair sections before fitting them, the wheels I have in mind are not entirely nova friendly lol

[DAVIDKEDENS]

Look forward to this build Bazil :)

Will it be at Crail on the 7th? ;) lol

[fossit85]

FFS another nova at this rate you will own 10 by 2020! at least one is a runner :p

[bazil]

Look forward to this build Bazil :)

Will it be at Crail on the 7th? ;) lol

Just need to pop it back on the trailer for crail lol


FFS another nova at this rate you will own 10 by 2020! at least one is a runner :p

I felt guilty about getting it easy with the black one Graeme so this will make up for it,

[gary_126]

Was that £36 the pair or each for the repair sections?

[bazil]

£36 for the pair Gary, £15 each and £6 vat

[brainsnova]

Was that £36 the pair or each for the repair sections?

Yes

[bazil]

Well decided to have a look at this today,
I must warn you that progress has been achieved so those who know how slow I work best sit down for this lol,

So my idea was to remove the inner wing brace panel and add a plate under it to add a little strength, sadly when I removed the brace panel I found the usual rust, although it doesn't look to bad I fancied a bit of practice, I last done panel beating around 12-15 years ago when I worked in a garage, so please excuse the ruffnes of my work as like almost all novas I'm a little rusty,

http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/2B05DBD1-5933-497F-85C7-619762DE76C8-5467-0000093E2EA3A7EC_zps312b35ee.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/F1610D97-8BFC-4D3F-AEF4-475464F734BF-5467-0000093E20F805AF_zps8ca8c944.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/271C758F-3988-43A0-AD8F-0D6D0B5550A0-5467-0000093E14E66CF3_zps47ac4a2a.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/A7A2872D-ED8A-4097-B53B-2F3B5F73B163-5467-0000093E0B07361A_zps901db2e5.jpg


So with the brace panel removed and most of the spot welds drilled out I take a piece of A3 card and make a ruff template of the section I want to remove, I make this template way larger than I need to so if need be I can cut a little more out if the rust goes further than I thought, ideally you want all the rot removed back to clean metal.

http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/FE5645DD-32BE-447F-A498-69D80B669F55-5467-0000093DE4F54133_zps4e933a48.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/B7D2D5ED-2FB4-4F23-AA09-6D45C6CDCF3B-5467-0000093DD906DFED_zps5386ccec.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/BC3DBA4F-11DD-453B-A27F-F7195C813EAB-5467-0000093DD0BDA74F_zpse885cb45.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/662AC0FD-3097-4A37-B1A9-CD82D67FAACE-5467-0000093DCAE3FE34_zpsf34360e1.jpg

[bazil]

So onto making the repair section,
Template trimmed to correct size then cut out on the sheet, again I leave the metal a little bigger than I need so I can work it into shape,
Once I'm happy with the outer shape of the card I transfer the actual size to the sheet then add the fold lines, I don't have a metal folder but a vice plus 2 lengths of angle iron and a soft mallet does the job,

http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/ECE094A4-AAB6-49B2-99A7-A1ED65161BDD-5467-0000093DC462DE1B_zpsf2ce60ca.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/47C2FA2B-FB5C-484A-8393-A690AC5C5D92-5467-0000093DABB11682_zps7f18d9f5.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/AA0561BB-0256-4BDF-81F1-F2302A362C65-5467-0000093D9F86ECC7_zps08acbb37.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/C654DE07-4F3B-4410-89AC-C9885C8B715A-5467-0000093D958FAA76_zpsd2964fc2.jpg

Now I'm happy with the ruff size and shape I trim and trim till its a good fit, then drill out the holes for plug welds, I spray the areas with weld through primer to ensure there is no bare metal between the faces to hopefully protect from surface rust.

http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/080F558B-80F5-4B8D-8335-6BF16B3AB803-5467-0000093D8EB5AFFF_zps4b5c4c3f.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/31925305-C894-4F20-92EE-5EB7216D3650-5467-0000093D89405EEC_zps970dd56a.jpg

Then clamp into place and get the welder fired up, it was giving me grief as its a £50 seally jobby, figured out the tension on the spool kept getting to much and causing the feed to slow down and splutter, lubed up the spindle and all was good, just a shame some of the welds suffered before I figured it out,

http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/BFD3DDFC-FB6F-4852-B499-BDD98EDE70FD-5467-0000093D83887BFE_zps885dd988.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/FAD9784E-B2FC-447B-934A-93B8EBB19999-5467-0000093D793DC83B_zps7235a210.jpg

Some penetration shots LOL

http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/2946D06A-8ECA-4E50-B33C-C7D32E6A6D7D-5467-0000093D063CF62F_zpse141e8cb.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/2395F1A2-5DF0-4C6B-87D7-DE16A824A24A-5467-0000093CFFE8564A_zpsd5cbf7ec.jpg

Then buff back the welds and prime again then add that extra plate I spoke about earlier

http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/765D3A36-F744-477C-9D25-03DEB986D2DF-5467-0000093CF9771BAF_zpsdf573460.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/E49E5B42-811E-41F5-9728-67EE487B07F4-5467-0000093CF227A4F3_zps70782041.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/73FD2255-DF84-4A39-97FF-72D0161BCFAF-5467-0000093CE9161B95_zpscadc555e.jpg

That's enough for one day, do some more soon.

Obviously I'm not going to be soooo involved with every update but it takes so long to do things like this.

[fossit85]

Holy Crap! By your standards you've done this years work quota :p

[vx kev]

Bazil has actually done a bit :eek:
Tidy welds them for a sealy jobby, i'd be happy with that :thumb:

[bazil]

Cheers lads, you know what's its like with a welder, were a bit like strangers to each other just now. Hopefully we will be good friends by the end of the week :)

[vx kev]

Yup, i'l be needing to get friendly with a welder soon i think lol

[Benn]

Bloody good work what you've done there.

[bazil]

Cheers Benn, I'm hoping I can tidy up the inside welds as I want a tidy finish rather just blooter it with sealer,

[tahir868]

Good work mate, look forward to seeing more :)

[bazil]

Cheers, the shell was stored for stock car racing and I only got it as the lad was moving on to using corsa C's as nova stuff was getting to rare and too expensive lol

[Edd]

Nice work

Use a small mini belt sander to clean them welds up on the inside, think there normally called bandfile, not 100%on that, I have one, really good for jobs like that

[bazil]

Sounds like a plan Edd, I'll ask my mate for a loan of his,

[shaunboy84]

Are the repairs ok mate ??

[bazil]

Are the repair ok mate ??

Aye, the way I've chosen to do it is in layers, so each layer covers each join so strength is retained, also there are no but joins, everything is overlapped and pluged then seam welded, it's a ball ache but the only way to do it

[shaunboy84]

looks gd mate, the repair panels for the rears gd quality ?

[boss]

Nice repair you get the practice in before you start the gsi ?

[bazil]

looks gd mate, the repair panels for the rears gd quality ?
There alright mate, mk1 style so ideal for you :)


Nice repair you get the practice in before you start the gsi ?

Yeah pretty much mate thanks :)

[shaunboy84]

good stuff a trip to autoscot then for me haha engine in process off stripdown ;)

[Balley]

Nice repair bazil.

[thegingerwhinger]

Cheers, the shell was stored for stock car racing and I only got it as the lad was moving on to using corsa C's as nova stuff was getting to rare and too expensive lol

Whats his name mate?

[bazil]

Mouser ?

[DAVIDKEDENS]

Love a project thread with loads of fabrication photos. :d

[thegingerwhinger]

Ah yeah they've got a few decent shells up for sale just now.

[NOV4_SPORT]

Very good mate, some nice fab skills going on wit that repair you will have it back on the road in no time at all

[bazil]

Cheers Iain, hoped to go up today for a few hours before my nightshift but my right eye is a touch iffy after yesterday, caught a flash so don't want to weld just incase it gets worse,

I think I might make a spit up for it this weekend to make life a bit easier,

[scott.parker]

****, your worse then me, I get mound at weekly, '' you got two novas an Astra and that bloody corsa, when you going to sort stuff and sell the Astra'', lol I will get round things eventually..

[Benn]

Use a small mini belt sander to clean them welds up on the inside, think there normally called bandfile, not 100%on that, I have one, really good for jobs like that

Power file too, i got a plug in one from machine mart, black and decker one is about £35-45. I used air ones at the bodyshop, then when rebuilding at home i kept saying i'll buy one, finally did... One of the best tools ever! As you can get in to everywhere with it. Im on my second one now.

[Southie]

Looking good Mr Bazil, it's all practice for getting the other build of your back on the road I take it?

[bazil]

Yeah that and using up what I have lying around, I've far too much stuff and can't be added selling it but don't want it to get damaged lying around so it's quite a handy build,

[bazil]

So went up to change a broken rear spring on the S3 and once I had done that I decided to do a couple of hours on this too, not much of an update to be fair lol

http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/70FB52C5-D68D-4921-B96E-5E5EA62CAAE9-3892-000005A5BA97AFCF_zps17f62699.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/002F2167-BAFF-44A3-95B1-369C0FF86D0C-3892-000005A5C7147F7C_zpsca536de9.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/8A4CC841-D039-4840-8B24-A7D8B1ED3CB5-3892-000005A5CF8AB133_zpsf0aa5205.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/CA380E8C-4D91-4E99-8E53-3C5CBDEAAF5C-3902-000005A6244B4060_zpsf6a63e4e.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/CF97400C-74D3-4D7E-9AD0-21D017C93C3E-3902-000005A6338E38E2_zps6e3fb946.jpg

Next is a small repair on the lower edge of the splash guard and then onto replacing the sill, they are not too bad but I'm going to change them to prevent any hassle in the future,

[brainsnova]

Nice job :thumb:

[L14MNP]

Power file too, i got a plug in one from machine mart, black and decker one is about £35-45. I used air ones at the bodyshop, then when rebuilding at home i kept saying i'll buy one, finally did... One of the best tools ever! As you can get in to everywhere with it. Im on my second one now.

This, all day. I bought a Ferme one online. The B&D ones were more like £70 iirc.

Such a great tool. Always wanted one. My mate bought one on the strength of my recommendation, and loves it too.

Toolstation for the sanding belts. They practically pay you to buy them. lol

[Balley]

Good work!

[Spudly]

Running yet ya tart :p



lol

[bazil]

BAHHHH HAHAHAHAHA lollollol

I was going to work on it tonight but it was a nice night for beer :)

[nova_niek]

bahhhh hahahahaha lollollol

i was going to work on it tonight but it was a nice night for beer :)

lol!

[marc69]

That's coming on really well, we will be eeing you at Knockhill with it then?

July is the next date, you should be ready by then lol

[bazil]

Yeah July 2017 lol

[shaunboy84]

my nova will be finished when its 30 year old haha

[craig green]

Re the opening post.
Bazil your Dad must be sound as fook. My Dad thinks Novas (all cars infact) are litter.

[bazil]

My dad has had his share of projects,

Used to do land rover trials, had an 88" chassis with a rover V8 for that, it's the first car I can remember I must have been about 4 lol

Opel kaddets, opel manta B rally car, opel manta A, lotus sunbeam, countless bmw's, bikes trikes and quads etc is what I grew up with, taking time off school to go and watch the rally's too was fun,

He bought himself a 57plate Fiesta ST brand new when he retired at 65 lol, the guys at work used to laugh and asked " Oi Tam have you borrowed your lads motor today ? " lol

He sold it after about a year, he just fancied a toy for a while,

I bet I'll be like him, old on the outside but still just a 17 year old in the head :)

[craig green]

LOL. My Dad's into bikes but just doesnt dig cars. Great project btw.

[bazil]

Well more fannying around today, really wanted to get the thing on its side so made a roll over jig today for the rear from old scrap I had lying around and the hub of the rear axle that will no be required anyway,

Hopefully should make life a touch easier as it can do full 360' rotation now :)

http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/0961D233-A1BC-479F-9982-CFA4D6E67EEA-8261-00000C42F282C64F_zpsc825b61e.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/4AE6C342-17E8-4ECF-8008-4CD73995D10D-8261-00000C42FEBE2060_zpsaa83ef0b.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/E1630EFC-A194-4652-A523-4DC9BE2BC6FE-8261-00000C430763F4BD_zpsd7355ff3.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/B1A2B8C0-ADD7-4D45-B1D9-A2910BC87E14-8261-00000C4313C25B08_zps072b4a8e.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/33DED942-AC38-4367-9FD9-88B58CC5B57D-8261-00000C432289365F_zps24167465.jpg
http://i790.photobucket.com/albums/yy181/Bazil_2468/SRIVALVER/B52A0180-1DF4-4278-8F27-6C37D2E8C258-8261-00000C43305D63CF_zps2da22ee0.jpg

[Balley]

Very nice!

[bazil]

The front jig is still bloody huge lol, so might trim it down. If the shed had a better floor I'd fit castors to move it about,

[dc1984]

Superb mate. Plenty of room for a few more novas now;)

[bazil]

Maybe just a S3 lol, thinking about a new daily and got insulted with £1k trade in on the S3 !!

[DAVIDKEDENS]

This not finished yet?

[EwanG]

Good stuff with the jig! Many small steps make a big difference!

[dc1984]

Maybe just a S3 lol, thinking about a new daily and got insulted with £1k trade in on the S3 !!

Seriously? What a joke mate, you could sell the engine for that.

[bazil]

I'd rather track the Cnut lol

[dc1984]

Now that sounds like fun:)

[bazil]

She won't let me :(

Gave up on the A1, cracking wee car but not right now

[dc1984]

Combo s3?

[bazil]

Naa, lightweight S3

See a 580bhp one today, sooooooo fookin want lol

[dc1984]

lollollol get it done then;)

[bazil]

You payin for it ???????

DDP?

Davie Deep pockets lol

[brainsnova]

You payin for it ???????

DDP?

Davie Deep pockets lol

Wtf lol he can't afford paint lol

[dc1984]

Wtf lol he can't afford paint lol


lollollol

[davidfox280585]

i cut 2 old axle stands up when we made one for the s1 and a motorway frame we aquired from work cost absolutely nothing

[bazil]

I never even thought about an axle stand!

Yup doing that for the front :)

[bazil]

Almost a year now and it hasn't seen much progress,

Time to cut my losses.

Shell for sale, includes 2 sills and 2 arch repair sections,
Needs a rear panel and boot corner repairs

£100 ( bear in mind the 4 panels supplied with it are worth £60 lol )

Can deliver locally for diesel money,

[bazil]

Sold lol