Nova 3dr Hatchback Road Rally Car Build Thread [Archive] - Performance Nova Group

dionbee

11-04-13, 02:04 PM

Hi, My Name's Dion, Been on the forum for a few years under another username and been looking and taking ideas from other build threads until I was ready to have my own!

The Car:
1.2 8v non-sunroof shell,
Was my road car last year, Bought standard and GSi'd the outside and tarted up a bit until I was happy with how it looked. Got bored and Decided I needed a more useable road car (Bought a Passat TDi) and decided to rally the nova.

This is the nova when It was on the road:

http://i146.photobucket.com/albums/r254/dionbee93/IMG_0528.jpg
How the car was when I got it and chucked my Compomotive Wheels on.

http://i146.photobucket.com/albums/r254/dionbee93/IMG_0523.jpg
Under the bonnet - OMP strut brace

http://i146.photobucket.com/albums/r254/dionbee93/IMG_0531.jpg
Rear when fitting new interior

http://i146.photobucket.com/albums/r254/dionbee93/IMG_0534.jpg
Standard Interior

http://i146.photobucket.com/albums/r254/dionbee93/IMG_0571.jpg
http://i146.photobucket.com/albums/r254/dionbee93/IMG_0570.jpg
Painted bumpers, Rear quarters and De-locked boot at the same time

That's how it was until I stopped driving it on the road Last Year..

Any comments etc. Much appreciated.

Dion!

dionbee

11-04-13, 04:47 PM

Here are some parts I have gathered for the car:

Kent Cam Vernier & NVO52 Cam
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/600160_10151570739745070_494115999_n.jpg

RFX Group A Wheels in 13"
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/487970_10151570739460070_234896902_n.jpg

Boot Pinned with Anodized Black Pins:
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/401311_10151570753740070_313854422_n.jpg

Quaife Quick-rack
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/72779_10151575868505070_1900260689_n.jpg

Bilstein Group A front struts (Including Protec Bumpy tar front and rear springs)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/599422_10151570757965070_484287602_n.jpg

4-2-1 Exhaust Manifold:
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/535788_10151570758030070_1418068743_n.jpg

Those are some of the parts I have bought, And a few weeks back i Bought a donor car (Rusty ex. Rally car project with a few good bits on it)
Here we are picking it up:
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/602226_10151572151615070_2054936413_n.jpg

Stripping the White Shell:
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/564499_10151574283585070_662627636_n.jpg
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/484685_10151574283675070_932589582_n.jpg
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/536218_10151574283835070_1789928180_n.jpg
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/599291_10151574284080070_404273061_n.jpg

Onto the Red one,
This is it before any work starts:
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/300159_10151570759880070_271465714_n.jpg

The White shell had a tidy straight SD cage (From what i've Gathered a hockly one) so mocked that in the red shell to see how it fitted, Also tried the seat in place for doorbar and diagonal clearance checking also steering:
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/39284_10151573845345070_671010309_n.jpg
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/599409_10151573845690070_1341354251_n.jpg
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/216734_10151573846190070_2088233671_n.jpg

Continued....

dionbee

11-04-13, 04:57 PM

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/549783_10151573845845070_1062218338_n.jpg
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/553314_10151573846010070_2100148366_n.jpg

Started on the Underside last week, Bought a spit from handling solutions, Best tool I've ever used, Makes the work much easier. Very happy with how clean the shell is if i'm honest. Found one piece of rust on the lower corner of the passenger rear arch but has been since cut out and welded inside and out.
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/408102_10151580847250070_731991824_n.jpg
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/482344_10151580847175070_629395179_n.jpg
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/149234_10151580847550070_1478098879_n.jpg

Bought Myself a Harry Hockly Motorsport Chassis Plating Kit, a pair of Topmount strengthening plates and got myself some 'coins' to plate up the circular grommet holes in the floorpan.
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/544903_10151582302680070_1804476746_n.jpg
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/553688_10151586394515070_1102282228_n.jpg

Started getting to work on the underseal, Seam welding, fitting the plating kit and Etch priming as I was going along:
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/45332_10151581698525070_129701760_n.jpg
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/733870_10151581698850070_989744146_n.jpg
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/64486_10151581698995070_1676780261_n.jpg
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/529612_10151581698655070_26120091_n.jpg
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/480665_10151581699050070_1500612447_n.jpg
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/544484_10151586395550070_1857357873_n.jpg
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/551511_10151586397845070_464987530_n.jpg
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/534122_10151586399075070_1169235090_n.jpg

Continued....

dionbee

11-04-13, 04:58 PM

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/72102_10151586398085070_1907150870_n.jpg
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/579722_10151586399140070_607240721_n.jpghttp://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/544635_10151586399230070_930086419_n.jpg
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/521919_10151586399380070_688248694_n.jpg

So basically that is where I'm at. I'm going back to uni next week so will be a fair few weeks until more beefy progress. I will be carrying on with parts buying and hopefully getting the beam etc. ready to bolt on.

Any comments etc. Are very much appreciated.

Thanks,

Dion!

peester

11-04-13, 05:10 PM

wow. top work. I assume the engine is out whilst its on the spit

dionbee

11-04-13, 05:17 PM

Cheers Mate, Yes The standard 1.2 engine was taken out and sold. The new 1.4 in mid-rebuild. Just standard with new gaskets etc and the Kent cam and vernier.

Dion!

dionbee

12-04-13, 08:38 PM

Back to uni next week so work on the shell will be at a halt for a while so ordered a few new parts today

- Full set of Polycarb Windows in a grey tint from ACW Motorsport Plastics using the PNG Discount! :)
- FIA Plumbed in fire extinguisher system from Demon Tweeks
- Flat 2mm Polycarb Doorcards (To be flocked at the same time as the dash)
- Alloy doorhandles for the inside (Standard plastic handles fouled the doorbars on the SD cage)

Any ideas and Tips/hints etc. Appreciated.

Dion!

dionbee

14-04-13, 02:25 PM

Bought a Bias Pedal box for the Nova This week (Got it through the post Friday) What are people's opinions on these? Going to be running 236mm Corsa GSi Brakes on the front (Grooved and vented with Ferodo/mintex or similar pads) and Standard drums on the back With EBC Heavy Duty (Black) shoes. Also will be running a Hydraulic handbrake with a bias adjuster inside the car. Do/should I need to be running a Remote Servo for this set up?

Dion!

jimbob-mcgrew

15-04-13, 11:22 PM

nice work DB :)

what kind of welder do you have ?

could you take a few extra pics of the brakes and calipers for me please mate, when you get round to fitting them :thumb:

dionbee

16-04-13, 03:00 PM

Cheers mate! :)

Yeah ofcourse I can. Will be while as I'm back in uni at the mo so just partshunting at the moment. Got the astra GTE calipers on there at the moment, but i felt they were too much of an overkill and kept locking up so going down to 236 with good discs and pads. Should be ample for a little 1400.

[Edit] I'm using my brothers Snap-On Mig. Took a while to get used to, but produces really nice welds once on the correct settings. I'm using 0.8 wire and 'Beergas' and it's been spot on. Wouldnt pay the higher price for argon mix personally as it's not a very large difference. Alsong as the metal is good and clean, you'll be fine!
Dion

dionbee

21-10-13, 08:12 PM

So, Its been a while since i updated this thread so here goes.

Car was prepped underneath and under the bonnet, fully seam welded and Harry hockly plating kit added. Etch primed, stonechipped and painted 2k Gloss White.
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/5599_10151697133490070_713092290_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/5599_10151697133490070_713092290_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/408258_10151674672260070_155319624_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/408258_10151674672260070_155319624_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/941549_10151698821900070_465207371_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/941549_10151698821900070_465207371_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/954751_10151698822085070_853836190_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/954751_10151698822085070_853836190_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/970742_10151702896565070_30112101_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/970742_10151702896565070_30112101_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1004749_10151702896185070_1708337610_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1004749_10151702896185070_1708337610_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1004744_10151702896625070_1784615469_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1004744_10151702896625070_1784615469_n.jpg.html)

More..

dionbee

21-10-13, 08:14 PM

Cage mounts and seat rails were added also and the inside all prepped, etch primed and painted the same colour as the shell. I painted the car myself in a mate's garage. Good enough for me!

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1014383_10151702897540070_312024362_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1014383_10151702897540070_312024362_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/992964_10151702898170070_825783020_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/992964_10151702898170070_825783020_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1017094_10151702898275070_512374943_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1017094_10151702898275070_512374943_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/954870_10151708173770070_1758386406_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/954870_10151708173770070_1758386406_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1014266_10151708173080070_315602715_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1014266_10151708173080070_315602715_n.jpg.html)

So theres the interior painted,

Dion!

dionbee

21-10-13, 08:16 PM

Shell in paint:

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1010498_10151716672180070_825028878_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1010498_10151716672180070_825028878_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1011454_10151716672235070_1650550972_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1011454_10151716672235070_1650550972_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1004739_10151716672320070_1350222457_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1004739_10151716672320070_1350222457_n.jpg.html)

Colour I Chose for the Car: Signal Violet.

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1044267_10151719707435070_2116412644_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1044267_10151719707435070_2116412644_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1010740_10151721032940070_488439316_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1010740_10151721032940070_488439316_n.jpg.html)

Preparing panels for paint:
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/946509_10151727896485070_996614135_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/946509_10151727896485070_996614135_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/7191_10151727896605070_1329432846_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/7191_10151727896605070_1329432846_n.jpg.html)

Dion!

dionbee

21-10-13, 08:19 PM

Starting to fit panels to the car:
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1005177_10151760056945070_153972542_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1005177_10151760056945070_153972542_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1013128_10151760057035070_1657197223_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1013128_10151760057035070_1657197223_n.jpg.html)

Wasn't happy with the cage so I bought these from Harry hockly motorsport and got a mate to start fitting a new rear cage into the car.
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1044770_10151759552905070_2134865907_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1044770_10151759552905070_2134865907_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/179189_10151767713385070_1644646905_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/179189_10151767713385070_1644646905_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1069924_10151767713480070_349316969_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1069924_10151767713480070_349316969_n.jpg.html)

Much Better - Powdercoated in Graphite grey metallic.

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/59528_10151794673960070_474059021_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/59528_10151794673960070_474059021_n.jpg.html)

Dion

dionbee

21-10-13, 08:24 PM

Meanwhile, when not in the workshop/garage i was making myself a double cowl dash using a LHD Drivers cowl and light switch panel for use with the navigators clock. All plastic welded to make sure its durable:
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/936797_10151649900775070_215670520_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/936797_10151649900775070_215670520_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/971819_10151649900890070_1954682774_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/971819_10151649900890070_1954682774_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/553770_10151649900820070_1952788292_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/553770_10151649900820070_1952788292_n.jpg.html)

Dash panels were then made using aluminium sheets (whole fusebox on the dash so its easier to fault find if needs be. (mocking on spare old dash)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/164948_10151773221395070_1911996536_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/164948_10151773221395070_1911996536_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1016345_10151773221130070_1354997302_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1016345_10151773221130070_1354997302_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1070043_10151773221075070_297210281_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1070043_10151773221075070_297210281_n.jpg.html)

Carbon Wrapped and Switches etc. Fitted. rev limiter has since been changed in favour of an OMEX system with launch control.

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/526459_10151828178300070_1277724181_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/526459_10151828178300070_1277724181_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/734350_10151828177565070_832612355_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/734350_10151828177565070_832612355_n.jpg.html)
Dash test fitted in car Fully flocked.
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1235172_10151857157495070_43211452_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1235172_10151857157495070_43211452_n.jpg.html)

Dion!

dionbee

21-10-13, 08:26 PM

Engine Wise I have decided to keep the standard 1.2. Its been machined down 3mm off the block. Flat top pistons. Full rebuild, new bearings and gaskets etc. Machined/ worked head, Kent NVO52 Cam and weber twin choke carb:

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/164467_10151789730120070_1962883804_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/164467_10151789730120070_1962883804_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1012431_10151789730020070_397027995_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1012431_10151789730020070_397027995_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/555253_10151789729820070_1618631031_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/555253_10151789729820070_1618631031_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/969751_10151789729970070_1431468630_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/969751_10151789729970070_1431468630_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/946709_10151803574650070_121223145_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/946709_10151803574650070_121223145_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/525736_10151832196350070_854135433_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/525736_10151832196350070_854135433_n.jpg.html)

Dion!

dionbee

21-10-13, 08:30 PM

Fuel and Brake lines ran inside the car along with a full brand new Wiring Loom:
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1004836_10151815272515070_1258868756_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1004836_10151815272515070_1258868756_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/560819_10151842457985070_824743760_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/560819_10151842457985070_824743760_n.jpg.html)

Fuel pump in sealed box:
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/535851_10151832200115070_689468432_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/535851_10151832200115070_689468432_n.jpg.html)

Rebuilt powdercoated and polybushed rear axle
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/578967_10151828351380070_1334569825_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/578967_10151828351380070_1334569825_n.jpg.html)

Machined flat and pressed in studs:
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1173766_10151828350250070_387914405_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1173766_10151828350250070_387914405_n.jpg.html)
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/548973_10151828350735070_389699987_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/548973_10151828350735070_389699987_n.jpg.html)

Front Corsa Sport calipers, new disks will machined bells and Ferodo DS3000 Pads and Pressed stud nuts. New bearings etc.

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1234934_10151875259110070_115717391_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1234934_10151875259110070_115717391_n.jpg.html)

Dion!

dionbee

21-10-13, 08:38 PM

Random Rest of the bits and Pieces of the Car:

flocked door cards and alloy Handles
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1186343_10151835063880070_2059660170_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1186343_10151835063880070_2059660170_n.jpg.html)

Wrapped Pillar Trims
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1000571_10151815273415070_136566404_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1000571_10151815273415070_136566404_n.jpg.html)

Pro-tec motorsport engine mount kit.
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1098355_10151813234565070_278017114_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1098355_10151813234565070_278017114_n.jpg.html)

Twin fan and new GSi radiator
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/996587_10151813235280070_1634159595_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/996587_10151813235280070_1634159595_n.jpg.html)

Pedalbox, and Quaife rack polybushed
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1013069_10151738800985070_539608621_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1013069_10151738800985070_539608621_n.jpg.html)

Bilstein suspension setup:
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1382864_10151955294100070_1744030779_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1382864_10151955294100070_1744030779_n.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1383382_10151955294270070_6716037_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1383382_10151955294270070_6716037_n.jpg.html)

Front end (New Spots)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1379427_10151929635020070_563335329_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1379427_10151929635020070_563335329_n.jpg.html)

Magnum XL black seats sidemounted with sabelt 3" harnesses
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/999471_10151883749485070_1679993457_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/999471_10151883749485070_1679993457_n.jpg.html)

Suede deep dish wheel, Corsa EPAS column with dash adjuster.
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1235968_10151883753580070_1019976902_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1235968_10151883753580070_1019976902_n.jpg.html)

Finished Car
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1377174_10151921583995070_1140924466_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1377174_10151921583995070_1140924466_n.jpg.html)

First Rally I did with it! Won fastest Vauxhall and Best presented Car award! :)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1380692_10151923672795070_591253768_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1380692_10151923672795070_591253768_n.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/66144_10151914959390070_1385735638_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/66144_10151914959390070_1385735638_n.jpg.html)

I think that's it. Probably missed a load of photos from the built but you get the general gist of it! Any comments or ideas etc welcome.

Thanks for looking,

Dion!

tomfromdelmonte

21-10-13, 09:04 PM

****!!! dude youre doing better than me!!! really nice welding too. Where did u get the 'coins' from? im after some myself... the fab shop said it would be a pain the ass so i may get squares and grind them to shape. They should be 34mm diameter if i recall correctly.

dionbee

21-10-13, 09:20 PM

haha, cheers bud, Them pictures are about a years worth of work on/off when I've been home from uni etc. and having time to do the stuff! I've welded most of the car up myself except the cage and seatrails. I got them from a local steel fab place. They just pressed them out for me to the size i req'd. Not too sure of the size mate, I placed them from the inside and welded from the outside then seamsealed both sides. Hope this Helps..

Dion!

jimbob-mcgrew

21-10-13, 10:54 PM

serious stuff dion :thumb:

dionbee

22-10-13, 05:01 PM

Cheers jimbob. Tried my best a few more little bits to do before the next rally and then get the new engine built! :)

Dion!

peester

22-10-13, 05:07 PM

what gear shifter/gearbox you fit in the end?

dionbee

22-10-13, 05:18 PM

At the moment peester its a standard f13cr but before the end of november theres a quaife f13cr straight cut gearkit and ZF plated LSD going in. Its mid rebuild at the mo!

Pictures soon..

Dion!

bazzap8389

22-10-13, 05:22 PM

Top work mate! Great job :)

dionbee

22-10-13, 05:27 PM

Cheers Bazza.. Means a lot.

Dion!

dgbnova#1

22-10-13, 06:18 PM

Some nice work there well done looks the part and obevisly working well!

dgbnova#1

22-10-13, 06:39 PM

Where about in north wales are you ?

dionbee

22-10-13, 06:43 PM

I'm near Caernarfon buddy. See that you're in birkenhead.

Dion!

dionbee

22-10-13, 08:04 PM

A little 'off' I had on the rally.. Slid sideways into a stone gatepost and caught the gate hanger. a little bit of re-shaping of the quarter happened and I lost my wing mirror doing so aswell!
Now though it's been all fixed, new mirror colour coded and While it was in the body shop had the lockable aerocatches fitted to the boot for security. (They do look a bit better than pins aswell I'd say.)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1174974_10151921584110070_1525725955_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1174974_10151921584110070_1525725955_n.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1377473_10151921583130070_1173603096_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1377473_10151921583130070_1173603096_n.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1374283_10151921583300070_1071065065_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1374283_10151921583300070_1071065065_n.jpg.html)

All knocked out, skimmed and painted:

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1377526_10151968972820070_253367489_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1377526_10151968972820070_253367489_n.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1380017_10151968972685070_371829772_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1380017_10151968972685070_371829772_n.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1001521_10151968972940070_256453273_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1001521_10151968972940070_256453273_n.jpg.html)

Aerocatches fitted and Rear bumper Painted aswell!

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1377495_10151968973170070_716714793_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1377495_10151968973170070_716714793_n.jpg.html)

Keep the comments and ideas coming.

Dion!

dionbee

24-10-13, 08:38 PM

Car is being insured again next week ready to be out again on the last weekend in November. Better get these little jobs done. getting a new box as there's a little gearbox oil leak that we can't diagnose even after fitting new seals and gaskets. bloody cars..

Dion!

dionbee

04-11-13, 07:36 PM

So last weekend I got an order of wet/dry sandpaper through and a few cutting compounds. I was very happy with the outcome of my DIY prep and paint but not been 100% happy with the roof of the car since i painted it. So had a go at wetsanding the roof and polishing it up using a rotary.
Not bad results considering.. Here is a 50/50 of the paintwork after the first run with the rotary:

http://i146.photobucket.com/albums/r254/dionbee93/photo.jpg (http://s146.photobucket.com/user/dionbee93/media/photo.jpg.html)

After 2 passes with harsh grit and then a further 2 with the finishing compound and some glaze wax.. Its not perfect and never will be, but i'm much happier now than i Was beforehand:

http://i146.photobucket.com/albums/r254/dionbee93/photo1.jpg (http://s146.photobucket.com/user/dionbee93/media/photo1.jpg.html)

On another note..
New clutch has arrived and the Quaife ATB Diff has been fitted in the rebuilt Quaife Straight Cut box. and Will be fitted this weekend when I'm home. Let the Squealing gears commence!

Also has anyone got any preferred Tie bar front bushes? I had a pair of new poly's on mine and after one rally they've disintegrated and causing a LOT of play. ideas without going rose-jointed appreciated.

Dion!

mk1nova_rich

04-11-13, 09:26 PM

Can't believe I havn't seen this thread...fantastic work pal :)

Looks great in that colour, I'd have been distraught if I'd dinged it though!!

What bushes were you using?

dionbee

05-11-13, 08:03 AM

Cheers mate, much appreciated. All part of the rallying game unfortunately! Innevitably going to happen, just a case then of repairing it and getting back out asap.

I can't remember exactly what brand mate, put the car on stands to spanner check underneath before next event and bits of polybush fell out..

Dion!

mk1nova_rich

05-11-13, 09:00 AM

What colour were they?

dionbee

05-11-13, 12:01 PM

They were orange mate.

As they say all clouds have a silver linings.. Last night my brother started stripping the car (sumguard, front suspension etc) for cleaning, greasing and fitting the box when he realised that the straight cut box wouldn't go on the 1.2 engine as the blocks different (started placement) and the flywheel's smaller.

So.. Back into the workshop, another gearbox was built using spares from the store room and the final spec is F13CR with a 4.2 CWP and a Zedef Plate Diff.

should be good, i'll have to learn to get used to driving with a plated and not on full lock every slot now..

Dion!

mk1nova_rich

05-11-13, 01:09 PM

Orange are probably Flo-flex...try Powerflex ones (purple) or the Rally Design ones

What gearbox did you try first, an F20??

dionbee

05-11-13, 02:25 PM

Yeah they probably are mate. Makes sense. Chucked some GSi tieslbars and the red rallydesign bushes on for now and i've got some purple pwerflex axle and bottom arm bushes in the post.

nope was an f13 but the flywheel/ clutch wouldn't match or something of that sort.
i'll ask my brother when i get home this weekend.

Dion

TeddyThom

05-11-13, 03:26 PM

Lovely colour dude. Are you going to go for bigger power at some point?

mk1nova_rich

05-11-13, 03:33 PM

dionbee

05-11-13, 04:09 PM

Lovely colour dude. Are you going to go for bigger power at some point?

Cheerst TeddyThom, yeah going for a similar spec to this one in a 1600 next year hopefully. Keeping it on carb and the same vernier / cam setup. Should give enough power for me.

Dion!

dionbee

05-11-13, 04:12 PM

I don't see why there would have been a problem as all small block gearboxes (F10, F13, F15..) have the same input shaft/clutch splines.

There are two variations of clutch and flywheel on the small block 8 valves BUT as long as you fit them as a matched pair then no issues as same gearbox will fit either type...the type you require depends on the block you have

1.6 and 1.4 MPi engines use the larger type, carb engines use the smaller. Because of this the starter motor is spaced further out on the MPi engines, but the only problem this causes is if you are trying to fit an F10 casing as the bellhousing is smaller than an F13 so won't fit over the larger flywheel and starter.

I can't say at the monent what the difference was as I havent been home yet, the 1.2 block's starter is closer to the centre and uses a smaller flywheel. I think it was a case of the stuff
I bought didn't fit on (new clutch etc.) atleast now i will have all those bits for when i get the 1600 ready next year.
I'll update when I know for certain.

Dion

mk1nova_rich

05-11-13, 04:32 PM

Ah right no worries, just a bit of info in case you didn't know :) Quite a few people seem to get confused with what fits what

dionbee

05-11-13, 05:03 PM

Yeah mate, to be honest, It was an expensive mistake when I found out what fitted and Didn't as I took a Flywheel to be machined, Lightened and Balanced for the new engine, to bring it home and realise it didn't fit on the 1200 engine! :( was proper gutted. It's here to use on another engine in the near future atleast.

Dion!

mk1nova_rich

05-11-13, 05:17 PM

Are you staying 8 valve with the new engine, or is 16 valve a possibility?

dionbee

05-11-13, 05:36 PM

Probably Staying 8v mate. A little more DIY potential with them I reckon. Also I've bought a lot of 8v specific bits to be honest (Exhaust, Solid Engine mounts etc.) So it's the most viable option at the moment. I'd be happy with about 110bhp if I'm honest. it'll be more than enough on the lanes.

Dion!

dionbee

05-11-13, 05:42 PM

To give you a little Idea, i had a 5 door Corsa 1400 before the nova. Which unfortunately my brother wrote off but a lot of the parts and ideas that are in the nova has come from this..

http://i146.photobucket.com/albums/r254/dionbee93/IMG_6729.jpg (http://s146.photobucket.com/user/dionbee93/media/IMG_6729.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/IMG_6731.jpg (http://s146.photobucket.com/user/dionbee93/media/IMG_6731.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/IMG_6735.jpg (http://s146.photobucket.com/user/dionbee93/media/IMG_6735.jpg.html)

Custom touch ;) 5Ri badges!
http://i146.photobucket.com/albums/r254/dionbee93/IMG_6734.jpg (http://s146.photobucket.com/user/dionbee93/media/IMG_6734.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/199030_10150181206170070_752070069_8906035_3161516 _n.jpg (http://s146.photobucket.com/user/dionbee93/media/199030_10150181206170070_752070069_8906035_3161516 _n.jpg.html)

Absolutely Loved the car, but thought instead of a reshell I'd use a nova instead.

Dion!

_Jake

05-11-13, 05:46 PM

it is possible to build a 1400 with 110hp, how restrictive is your class on engine mods?

dionbee

05-11-13, 05:54 PM

I know that mate. But acheivable much cheaper with a 1600 I reckon. And as well, i want it to be ultra reliable rather than squeezing All I can from a 1400. Fairly open with mods, Aslong as its not on twin carbs etc. you can do pretty much what you want.

Dion!

_Jake

05-11-13, 05:58 PM

fair enough :) I take it your allowed MPi like the standard GTE/GSi engines then?

dionbee

05-11-13, 06:07 PM

Yep buddy, You're allowed MPi, loads of the Corsa SRi Lads swear by them, But I think there's something about the sound of a Carb that makes it a little more desirable ;)

Dion!

_Jake

05-11-13, 06:31 PM

fair enough lol lol

dionbee

10-11-13, 04:13 PM

So, the gearbox was fitted over the weekend and Took the car for a quick blast. The 'box has totally transformed the Car.. Can't wait until i've got a little more power next year. Should be a well sorted car then.

Also, My sumpguard has gone to be welded up again (Adding 16mm aluminium blocks to each corner to act as stress plates to strengthen the mounting points and to lower the guard a little as I wasn't perfectly happy with how close it was to the sump/exhaust. Will add pictures when I'm home next weekend.

Dion!

dionbee

25-11-13, 06:58 PM

Well, even though a bit last minute.. All the prep work was finished on the Nova for last weekend..

Welded the front and rear sumpguard mounting brackets to space them 16mm further down. 26mm on all corners and 10mm guard. Might look a little overkill but I'd rather be safe than sorry..

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/6F2B1B4B-DB87-4529-8882-30974BD53325.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/6F2B1B4B-DB87-4529-8882-30974BD53325.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1A14E854-CF59-4A34-84FC-43E6FCA48896.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1A14E854-CF59-4A34-84FC-43E6FCA48896.jpg.html)

A bit of spanner checking and the road car looking a bit sorry for itself..

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/A958E292-A555-4353-8420-A4788E2B1A1C.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/A958E292-A555-4353-8420-A4788E2B1A1C.jpg.html)

Morning after the Rally.. LSD really transformed the car. A tidy 1st in Class and 2nd Overall Position. Chuffed to bits with it!

http://i146.photobucket.com/albums/r254/dionbee93/NovaJamesTrenholme.jpg (http://s146.photobucket.com/user/dionbee93/media/NovaJamesTrenholme.jpg.html)

Any comments etc. much appreciated.

Dion!

mk1nova_rich

25-11-13, 08:36 PM

Looks waaay too clean to rally lol...sump guard looks good, whats the purpose of the slots in the front of the sump guard - cooling??

dionbee

25-11-13, 08:54 PM

haha, no such thing! the purpose is to tow the car if needs be mate!

Dion

mk1nova_rich

25-11-13, 09:05 PM

Ah yeh good idea lol I forgot to say well done on the result :thumb:

scott.parker

25-11-13, 09:06 PM

How did i not see this before, its awesome!

dionbee

25-11-13, 09:15 PM

Cheers boys.. Means a lot!

Dion.

tomfromdelmonte

25-11-13, 10:37 PM

Ive never seen a sumpguard made out of chequerplate before. Do you know how much it weighs roughly?

The harry hockley jobbies are about 200 notes which seems like a lot. Pretty sure its just 10mm duraluminium plasma cut to shape and bent at the front with some brackets welded on. How did you get yours done?

Car looks good as always mate and im pretty jealous that youre actually getting to use yours in anger!!

dionbee

25-11-13, 10:59 PM

Hi tom. Mine's an aluminium exact copy of a hockly one(minus the spacing plates) So it fits on using the hockly brackets in the chassis rails under the car (in the plating kit)
it does weigh a fair amount but to be honest. I couldn't justify £200 for a duraliminium one just for weight reduction.

haha, cheers bud, the time will come soon enough for yours don't worry. Especially with the pace you're. Cracking on with it at the moment! Don't be tempted to rush the finishing stages, its all about taking time to fit stuff properly first time 'round!

Dion.

tomfromdelmonte

25-11-13, 11:04 PM

Dion, funny you should say that about taking the time to fit things properly... those two brackets in the plating kit, i couldnt figure out where the bloody things went so i havent welded them on yet :(

Didnt want to weld them on and then find the holes are out or they dont match up with the guard!

Not sure whether im going to buy a hockley guard or try snd fabricate one. I could get some aluminium wire for my welder and just go for it. I used to weld a bit of ally back in the day so i kind of know what to expect. worth looking into probably.

dionbee

26-11-13, 11:50 AM

typical, I wasn't sure at first.. you drill a large hole in the chassis rail and place the wheelnut side through ans weld the plated on top. This acts like a captive nut to hold your sumpguard using the L shaped brackets hockly supply.

You honestly can't go wrong with making your own guard. If its thick enough steel or alu It'll be fine. Try and skid it if you can or use a thicker sheet (10mm is ideal or 5mm with 5mm skids)

Dion.

tomfromdelmonte

26-11-13, 01:24 PM

What does skid it mean Dion?

ive heard of skidded stuff but i cant picture it.

wwinstanley

26-11-13, 03:01 PM

Only just stumbled across this! Looking good though, pretty impressive paint for a home job!
What sort of rallying are you into? Just started stage rallying myself this year and currently building a new nova so looking for some inspiration!

wwinstanley

26-11-13, 03:17 PM

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1235172_10151857157495070_43211452_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1235172_10151857157495070_43211452_n.jpg.html)

And what rally clock is that mate, been looking for a nice sized one for a while.

1396rally

26-11-13, 11:27 PM

And what rally clock is that mate, been looking for a nice sized one for a while.

Looks like a circuit innovations (http://www.circuit-innovations.co.uk/digitalclock4.html) one

I have just got a Matt Pearce (http://mattpearcerally.com/) rally clock

Or the Roamertime (http://www.thebasicroamer.co.uk/epages/es133467.sf/en_GB/?ObjectPath=/Shops/es133467/Products/TIMING-1-RT) one

I prefer the Matt Pearce version over the circuit innovations one, as it has a battery backup and does not loose the time when switched off.

gary_126

28-11-13, 05:10 AM

Great car! nice attention to detail. Are you still using the 1200? You seem to be getting great results, so intrested to know what spec/figures the engine is.

Peredur

28-11-13, 09:19 AM

What does skid it mean Dion?

ive heard of skidded stuff but i cant picture it.

He means a skidded guard with longitudinal strips of alloy stich welded to the main guard sheet.

Cracking progress tom, wish I could get so much done on mine

Peredur

28-11-13, 09:20 AM

And what rally clock is that mate, been looking for a nice sized one for a while.

Circuit Innovations make them. Best clock for the lanes short of spending £100 on a RoamerTime unit

dionbee

28-11-13, 05:00 PM

Hi Tom, yeah as Peredur said, running strips along the guard to take the impact/hit the ground where they can be replaced when worn rather than a new guard etc.

Hi Gary, yeah i'm still running the 1200 engine for now. Fair bit of work has been done.. And to be fair goes well for what it is. Still yet to set it up on the rollers and get figures but basic spec is:

1200 8v block
decked 3mm
skimmed head, ported and cleaned
machined flat top pistons
all new bearing and gaskets etc.
kent NVO52 fast road cam
Kent adjustable vernier pulley

Cheers for the nice comments,

Dion

gary_126

29-11-13, 05:26 AM

Cool, wonder what gains you have achieved? As 1.2 tuning is something most people just dont bother with. Keep up the good work

tomfomthenorth

01-12-13, 07:08 PM

Mate that is inspirational, looks too nice to rally! What event did you enter, surprised they let you run without helmets on?

dionbee

01-12-13, 07:14 PM

A Rolling Road and Tune-up session is in the Pipeline Gary.. Will be nice to know what a home built Engine has gained! Cheers Tom, Means a lot, I do Road Rally events where helmets are not required, Your RAF rally car looks good, Should be a weapon when its ready to go out again!

Dion

Andy

01-12-13, 08:00 PM

Just read the full thread,great build and a very nice finish.
Nice to see it being used what novas do best-motorsport.
Keep up the good work and updates

dionbee

01-12-13, 08:30 PM

Cheers Andy, Its being used exactly as it should! :) I don't personally see the point of a nova as a road car.. They're uncomfortable, Tiny and compared to the newer stuff, VERY SLOW!

The handle well with a few bits and pieces and are very easy to maintain therefore would be a crime not to rally it. Each to their own, but if I had one as a road car It would probably be driven in anger anyway!!

Dion.

dionbee

21-01-14, 11:34 AM

Its Been a Little While Since I've updated this thread. I hope everyone had a nice Christmas and is ready for another year of Tinkering!!

Since the last update, car has been for a rolling road Session and tune-up:
Decent gains over standard to especially thinking that the engine is a budget 1.2 build.
Standard : 37bhp @ Wheels and 44bhp @ Flywheel
Mine : 58bhp @ Wheels and 70bhp @ Flywheel
Safe to say I was more than happy :) Cheers to A.B Motorsport for sorting it out for me!
http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/E6015BFE-9C45-420A-862B-6B9DE6BEDF75.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/E6015BFE-9C45-420A-862B-6B9DE6BEDF75.jpg.html)

Here are some pictures of the car in action Last year:

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/8F26E3E3-922F-43EB-8D49-4C3CD68DEABA.png (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/8F26E3E3-922F-43EB-8D49-4C3CD68DEABA.png.html)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/5FEF42F0-A92D-4104-8EB2-6FA1AFE04EC5.png (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/5FEF42F0-A92D-4104-8EB2-6FA1AFE04EC5.png.html)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/4548D547-B8BD-4938-9679-17D625CCFA6E.png (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/4548D547-B8BD-4938-9679-17D625CCFA6E.png.html)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/A9238476-867F-4F6C-8E0D-A0565FABCFE2.png (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/A9238476-867F-4F6C-8E0D-A0565FABCFE2.png.html)

I've entered the Welsh Road Rally Championship this year, 12 rallies, 8 counting to score for the Championship.. Should be Fun!
Tyres are ready, car is set-up, just need to fit the new Ducati exhaust can and I'm ready to go!
Also Fitted a New gearbox, Now running a Quaife Straight Cut F13cr Gearkit. Quaife ATB LSD and a 4.3 CWP. (On the lookout for a 4.5/4.8 if anyone has one!!)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/D4A90138-5BEC-4188-8C5A-F065C79B1694.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/D4A90138-5BEC-4188-8C5A-F065C79B1694.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/251FDF9A-6BD1-4123-9B91-84CCF2E2DAB7.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/251FDF9A-6BD1-4123-9B91-84CCF2E2DAB7.jpg.html)

I am also 21 today, So got the best Cake I Could've wished for!

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/B7E163C4-FEFE-4E88-9472-69FFFF53C560.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/B7E163C4-FEFE-4E88-9472-69FFFF53C560.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/D8AA0A9A-170A-4C97-B56F-EF5000C57AA3.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/D8AA0A9A-170A-4C97-B56F-EF5000C57AA3.jpg.html)

Dion.

novalew

23-01-14, 11:19 PM

love the build mate fantastic efforts.

love the cake too

dionbee

23-01-14, 11:53 PM

Cheers mate, much appreciated. I loved the cake, was delicious too!!

Dion.

dionbee

05-02-14, 11:00 PM

Well, First Rally of the year out with the car and unfortunately my efforts ended early after around 10miles competitive mileage the coil decided to crack, and the rotorarm disintegrated and chucked a hole in the side of the dizzy cap!

So, 3 new caps, 3 new coils and 3 new rotorarms on order so I'll always have spares on event if it happens again. Absolutely gutted but that's rallying I guess!!

Dion

AndrewC

10-05-14, 12:47 AM

Great build and even better to see you out there winning stuff. If you get chance I'd appreciate more pics and description of your fuel setup including the ammo box, pump, lines through bulkhead etc.

dionbee

11-05-14, 11:59 AM

Cheers Andrew,
I'll be going up to the unit in the next few days to spanner check the car ready for the next event, i'll grab some pictures for you then, Also need to update this as a few things have gone on since last time..
Engine change being just one.

Watch this space.. Haha!

Dion

dionbee

11-05-14, 12:53 PM

I'll update for the time being with what I have saved
(Apologies for the mostly poor iPad quality pictures!)

Here are some pictures of the car in action since last time:

Ready for action..

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg4-2.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg4-2.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg2-5.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg2-5.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg1-5.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg1-5.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg3-5.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg3-5.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg4-4.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg4-4.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg2-4.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg2-4.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg1-4.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg1-4.jpg.html)

Continued...

dionbee

11-05-14, 12:56 PM

Updated regarding the car.. As said above I've fitted a new engine since.

now running a 1600cc 8v engine on a single 40 Weber Carb.

Bogg Bro's manifold:

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg1-1.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg1-1.jpg.html)

Carb offered up:

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg2-1.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg2-1.jpg.html)

Wrapped 4-2-1 Manifold ready to fit:

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg2-2.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg2-2.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg1-2.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg1-2.jpg.html)

Ready to be fitted..

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg4-3.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg4-3.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg3-4.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg3-4.jpg.html)

Continued...

dionbee

11-05-14, 01:01 PM

Engine Fitted in the car:

Have had to fit filter 'socks' since as the ITG unit was fouling the clutch cable.. All sorted now.

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg4-1.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg4-1.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg3-2.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg3-2.jpg.html)

New vented disks and Mintex 1155 pads to try this time:

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg3-3.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg3-3.jpg.html)

Filter king & fuel pressure reg:

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg2-3.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg2-3.jpg.html)

New inner & outer CV's and gaiters etc:

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg3-1.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg3-1.jpg.html)

And a quick few just to prove that the car isn't a trailer queen and that it does infact get used in real anger!
Sumpguard brackets after a VERY rough Gremlin rally 2014 (Harry hockly one's ordered and fitted since)

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg4.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg4.jpg.html)

And how the car was after the event!

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg3.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg3.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg1.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg1.jpg.html)

And how it stands following a Steam clean and awaiting a spanner check before the next event.

http://i146.photobucket.com/albums/r254/dionbee93/imagejpg5-1.jpg (http://s146.photobucket.com/user/dionbee93/media/imagejpg5-1.jpg.html)

Any comments much appreciated - keep em coming.

Dion

dgbnova#1

11-05-14, 06:04 PM

Nice to see it in person and great to see it being driven hard lol how did your new engine feel and the carb setup ?

dionbee

11-05-14, 06:45 PM

Cheers mate!

Engine feels brilliant to be fair, produced 130@flywheel which i'm more than happy about.
Carb is very responsive and sounds brilliant. Ran like a dog until i took a trip to see Dave Willett race engines - reccomended to anyone running any vauxhall engine.

Dion

dionbee

26-11-14, 09:21 PM

Been a while since i've last updated this, quite a lot has happened since. A few rallies to start off.. The classic tracks Road rally last summer - changed bumpers to standard to avoid stonechips to the cc'd GSi items.. Thought it looked a lot better in the grey guise.

http://i146.photobucket.com/albums/r254/dionbee93/6ddbcc15dda1e71864811c396876e678.jpg

http://i146.photobucket.com/albums/r254/dionbee93/6212a6db6f39375c20c10f1e87633a04.jpg

http://i146.photobucket.com/albums/r254/dionbee93/577a9921b859c06c594717d935fed71d.jpg

Finishin pg in 13th overall position and winning my class was a good result for the car and unfortunately (unbeknowing ti me) would have been the car's last event!

So that brings us to where i am now.. Unfortunately the car caught fire, bigstyle a few weeks after the rally.
estimated at £4.500 of damage (parts only) i was gutted to say the least. Shell seems fine but needs a LOT of work.

only picture I have at the moment..

http://i146.photobucket.com/albums/r254/dionbee93/8d274215eb78cf81194bb4c3180a2c60.jpg

Stripped it down and thrown all the melted bits and booked the car in to Harry Hockly Motorsport for february for a Full Wel-In multipoint roll cage, shell bead blast and sill jacking tubes etc.

Part collecting at the moment and will update when i can, if anybody can help with some standard (non melted) front end parts, grilles, water bottles, etc. please get in touch. Thanks.

Dion

marc69

26-11-14, 09:57 PM

That's a stunning build, great to see it rallying. I have a mk2 I broke so will have standard bits but....am in Aberdeen!

totalnova

26-11-14, 11:26 PM

Really sorry to hear your bad news, any idea what the caused the fire?

dionbee

27-11-14, 07:45 PM

Cheers guys.. We've no idea what caused it at all.. Bit if a weird one. I'm just glad it happened parked up rather than on an event or on the road.

Dion

dionbee

20-02-15, 02:32 AM

Been a while since i Updated this thread.. as stated previous, the car has been with Harry Hockly Motorsport, having a Bead blast, Full weld in roll cage, Sill tubes and a few other bits and pieces done to the shell. Here are some pictures of removal of the fire damage.

Bulkhead:
http://i146.photobucket.com/albums/r254/dionbee93/AF50FB07-378F-45A7-B121-3BA1E1110FF0.png (http://s146.photobucket.com/user/dionbee93/media/AF50FB07-378F-45A7-B121-3BA1E1110FF0.png.html)

http://i146.photobucket.com/albums/r254/dionbee93/25087394-4790-423F-9882-4120CC7EFFD6.jpg (http://s146.photobucket.com/user/dionbee93/media/25087394-4790-423F-9882-4120CC7EFFD6.jpg.html)

Half of the floorpans done: rears have no damage atall.
http://i146.photobucket.com/albums/r254/dionbee93/68149289-C2F3-4A48-8AB7-E01A0C758677.jpg (http://s146.photobucket.com/user/dionbee93/media/68149289-C2F3-4A48-8AB7-E01A0C758677.jpg.html)

Underneath:
http://i146.photobucket.com/albums/r254/dionbee93/9D62E155-BD29-4BE4-AFA0-5BEFD945B5B9.jpg (http://s146.photobucket.com/user/dionbee93/media/9D62E155-BD29-4BE4-AFA0-5BEFD945B5B9.jpg.html)

more pictures of the shell when I get it back from Hockly's. It's ready but i'm yet to sort a date for collection. Can't wait for getting this car back out im the lanes!!

Dion