View Full Version : Johnny's Nova builds
Johnny A
18-09-13, 09:25 PM
I hope you guys like a good story!
It all started with my first decent Nova, an F-reg GTE with the number plate 'F47 SEF' (factory issued) back in early 2001:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-frc1/733802_10153210566955214_1859525399_n.jpg
After an 8 month stint without really doing anything to him I rear ended a Cav GSi :roll: I managed to twist the chassis of the Cav but surprisingly the use of a front strut brack and a totally rotton front cross member made a sort of energy absorbing front end lol. The nova needed nothing more than a new front end. Whilst a new front end went on it was decided it was time for an XE (don't ask me why it was a good idea to install a more powerful engine considering I couldn't really handle a 100bhp 1.6 8v). Anyway it worked out for the best and a modding streak led to a C20LET and loads of mods that back then were rare (Cav shifter, electric sunroof, windows and wing mirrors):
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn2/1208941_10153210569275214_1086193582_n.jpg
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn1/68460_10152279833180214_1371764097_n.jpg
SEF went through 3 F20 gearboxes in 8 months before a major issue occurred. I was coming back from Southend cruise (ahhh memories) and I went round a corner quite hard, I straightened up and the steering felt vague. The next day I found both front suspension turrets had cracked from top to bottom and on one side the only thing holding the turret together was the factory turret strengthening tops :eek:
It was at this stage decided to put the plate on retention and break the car to recoup money to pay off the credit card I used to build the damn thing :d
I went through a few more Novas, all saloons (this was before they were cool).
An a-reg brown one, intended to do something fruity with it... until someone rear ended me at a roundabout:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/1208727_10153210682980214_1718446823_n.jpg
A shed of a more door, basic shell was solid but the panels were rotton and held together with gaffer tape. An XE provided many a fun race with the local badboys lol
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash4/482486_10152576574870214_826487050_n.jpg
I had plans to revive SEF in a 2dr saloon shell, I made up a photoshop of what I wanted him to look like:
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash3/579687_10153210701890214_753546788_n.jpg
About 4 years ago I found a Nova saloon shell perfect for the job:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash3/20544_447400690213_7318665_n.jpg
I wanted to push myself with modifications so decided to convert the car to rear wheel drive with the engine in the front. A tall order even now, so I got some help from a former friend. Trouble now looking back there were a lot of things I would have done differently and I think were done not so much incorrectly but could have been better. At the time I didn't know much about suspension geometry and taking advise from my friend I think it wasn't done well.
Unlike Austin's Mk2 Escort-based RWD Nova and recently Simps 200SX based RWD Nova they have sacrificed comfort/usability for road use in favour of a track-based car for the weekend. I wanted it as a badass do-everything daily driver so I had to have the engine further forward in the bay then i'd have liked for weight balance but hey.
Before I show some images I'd like to point out there are things wrong/not ideal with the design (mainly front hubs need redesigning and the retention of the semi trailing arm will probably make the car very tail happy) but please if you are narrow minded enough to blindly slag it off please keep it to yourself. With that in mind I am more than happy to listen to your input should you have an idea to enhance/fix the issues that don't involve a complete redesign.
Johnny A
18-09-13, 09:25 PM
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn1/20544_447436945213_967366_n.jpg
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn1/p206x206/20544_447438025213_7184612_n.jpg
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/20544_447477790213_7583435_n.jpg
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/20544_447467630213_7482163_n.jpg
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/p206x206/20544_447478130213_5945097_n.jpg
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn1/20544_470144670213_7496643_n.jpg
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn2/167501_10150354590415214_834459_n.jpg
At about the same time I completed the chassis I fell out with my friend over various things (one thing being the design problems with the car) and him being kicked out of his unit (where the nova was worked on). After that I brought it home and lost interest :(
Since then it's been moth balled at home then later my own unit. I went onto Vauxhall Carltons and learnt an absolute bucket load on suspension design and geometry, recently finishing off my estate which outhandles most scoobies and evos... not bad for something weighing 1.4 tonnes :)
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn1/944729_10152847680415214_68126904_n.jpg
Recently I wanted to revive SEF and my love for Novas. I sourced a 3dr shell in great condition and a donor XE Calibra:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-frc3/1000594_10153075679665214_903989771_n.jpg
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn1/q77/s720x720/1236559_10153199016450214_1522171673_n.jpg
I am not sure the XE build will be very interesting, let's face it there are so many of the buggers about!! But it will have a few choice and somewhat unique mods that may interest people. One is the use of an Astra turbo F23 gearbox (cable shift and hydraulic clutch), Z20LET oil cooler (sits on the back of the block and uses coolant to cool the oil), Corsa-B electric power steering and the use of Corsa-C 1.8SRi rear hubs and discs.
Originally I bought this to be my daily driver but at the same time my mum wants a nice Nova as a retirement car, finding another Nova 3dr seems problematic to say the least. So I went back to my Saloon which at this stage is covered in a thick layer of dust and crap, I had a long think about the design and how difficult it would be to bring the car into service. Several days ago I made the decision to build SEF as planned over the next month, then when done finish off the RWD Nova Saloon, I am not sure as to what engine to use in the Saloon - it was originally designed to take an XE/LET but I keep having filthy thoughts about a B204. When the saloon is done I will give SEF to mumsie (because lets face it, we all want to look after our mums and make them happy).
So this thread will be about me bolting stuff together and welding stuff, so as before I encourage constructive crititism and ideas but I have no time for morons who just slag off my ways of doing things. Please keep this thread civil :thumb:
On saturday I am weighing the Calibra shell in then I start on SEF by getting the engine installed.
John.
corsakid
18-09-13, 10:05 PM
I saw the Carlton at silver stone the other week, I went up for time attack mainly but was pleasantly surprised on one of the track session to see you Carlton it cornered like it was on rails and went very well aswell thumbs up mate
Looking forward to seeing the progress John.... big fan of the camo Carlton and the work your doing with it!
Nick.
My pal has a F23 on his nova, seems to work well and cable shift is much better than rod linkage
As for the carlton how did you make it handle, simply by trial and error or read some kind of motorsport related books about it?
Yo! :) finish the rwd nova! :)
nice selction you have! on the rwd nova what gearbox/rear axel and steering rack are you using?
Its good to see you back on the site properly mate and look forward to the progress
Johnny A
18-09-13, 10:41 PM
My pal has a F23 on his nova, seems to work well and cable shift is much better than rod linkage
As for the carlton how did you make it handle, simply by trial and error or read some kind of motorsport related books about it?
Yeah the F23 was from my old Astra coupe turbo, I added a short shift and tweaked the shifter to remove any play. It's a superb setup and I don't see why it can't be adapted to work on a nova - however I have a few slight concerns about the cable length.
I didn't buy any books, I found some articles online about geometry and motorsport modifications for BTCC/DTM cars. I also found a little info and pictures from the 90's BTCC Cavs and DTM Omega-A's (Carltons). I then used dual perch coilovers from various aftermarket jap donors to build coilovers to suit. The front hubs needed a lot of work to correct the geometry, the back was simply a diff raise (30mm), camber correction and the addition of turrets (only because the estates don't have rear shocker turrets).
Its good to see you back on the site properly mate and look forward to the progress
x2. :)
Johnny A
18-09-13, 10:45 PM
nice selction you have! on the rwd nova what gearbox/rear axel and steering rack are you using?
Well when I originally built it I built the tunnel around a R25-28 Omega manual box (found in all V6 models) along with the forward section of the prop (with centre bearing). The rear diff is a Lotus Carlton item.. perhaps a little overkill!
The steering rack is a Corsa-A LHD rack flipped upside down, I had to do this because the hubs are actuated from the front rather than the back so I needed to reverse the reversal if that makes sense? It works perfectly although it retains the 3.8 turns lock to lock, I plan to make my own hub carriers up front with shorter arms on to reduce the throw and chance that ratio.
Well that's a blast from the past! My brother had the front view pic of SEF on his bedroom wall for years after buying the speedlines off you for his corsa b.
Thats an interesting read, your original GTE looked awesome, i cant wait to see more progress here:thumb:
maddogdaz666
19-09-13, 09:29 AM
Yay finally!
if you ever get a chance to get anymore pics the rwd nova setup that would be great. i am thinking of going rwd with my let nova project using an omega as a doner car. i would be using the gearbox, rear diff setup but will have to do alot more research.
I can't wait to see you cracking on with the RWD saloon.
Johnny A
19-09-13, 06:59 PM
if you ever get a chance to get anymore pics the rwd nova setup that would be great. i am thinking of going rwd with my let nova project using an omega as a doner car. i would be using the gearbox, rear diff setup but will have to do alot more research.
To be honest mate the way I have done it isn't ideal, it makes use of the factory trailing arm frame heavily modded to accept a rear drive assembly. I was advised to use this design as apparently its how many hot rods were converted. Either way my setup will work but since then I have found an easier setup that would yeild much better results. Basically do with the kit car boys do:
http://www.clubcobra.com/forums/attachments/scratch-builders-forum/10462d1121060888-drawings-p002rearsus2_2.jpg
Then weld into a Nova!
Johnny A
19-09-13, 06:59 PM
Well that's a blast from the past! My brother had the front view pic of SEF on his bedroom wall for years after buying the speedlines off you for his corsa b.
Haha Sef was a pin up lol
Johnny A
19-09-13, 07:56 PM
I lot of my original pictures are missing from my HDD but here are a few as requested:
Rear hub, suspension assembly:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash3/20544_447453655213_6038089_n.jpg
Pretty sure they are vectra front hubs
The tunnel half way through construction:
The design allows the exhaust to run along side the box, as the propshaft starts the exhaust tucks under to make sure everything is mounted above the floorpan
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn1/20544_447438100213_6384262_n.jpg
DAVIDKEDENS
19-09-13, 08:26 PM
Some nice work put in here.
Look forward to some progress, the Carlton is awesome too.
Dave :)
Johnny A
19-09-13, 08:52 PM
I don't suppose anyone has a Saab B204 lump to measure up?? I would love one in the saloon but I only just managed to squeeze an XE in the bay with the bonnet shut!
scottmasterton
19-09-13, 09:15 PM
Johnny, do you mind taking some more photos of the steering column and how you altered things to make it work on the inside and the outside?
Johnny A
19-09-13, 09:26 PM
I am going to be very busy when I am up the unit but if I remember I will
The Simps
19-09-13, 09:39 PM
Good to see you cracking on mate :)
Johnny A
19-09-13, 09:42 PM
Good to see you cracking on mate :)
Cheers, I am still going to proceed with the plan I discussed via PM but with another shell
The Simps
19-09-13, 09:51 PM
Refresh my memory mate! I've deleted the PMs and slept a few times since then! lol
:(
http://img.photobucket.com/albums/v11/CorsaNova/Nova/7cc9a88e.jpg
http://img.photobucket.com/albums/v11/CorsaNova/Nova/b7caa2ef.jpg
Johnny A
19-09-13, 10:12 PM
:(
http://img.photobucket.com/albums/v11/CorsaNova/Nova/7cc9a88e.jpg
http://img.photobucket.com/albums/v11/CorsaNova/Nova/b7caa2ef.jpg
Yep that was her, creased all the rear floor :(
Yep that was her, creased all the rear floor :(
:cry:
scottmasterton
20-09-13, 07:31 AM
I am going to be very busy when I am up the unit but if I remember I will
Great :) thank you
Is that the one you had the first time I met you Mark at the Milton Keynes meet?
Is that the one you had the first time I met you Mark at the Milton Keynes meet?
Yep.
Johnny A
21-09-13, 07:41 PM
Update:
After weighing in the calibra donor I managed to get a little prep work done on the XE, I fitted the Z20LET oil cooler, refitted the inlet manifold with modded coolant pipes and cleaned the unit up.
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn2/1239534_10153222966150214_1200035816_n.jpg
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/1238848_10153222966510214_254966738_n.jpg
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/1235005_10153222966970214_554695746_n.jpg
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash3/923383_10153222967845214_519923852_n.jpg
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn1/14166_10153222968155214_1109070478_n.jpg
So far the only downside is that the ICV needs relocating which to be fair isn't a bad thing
Ive often wonderd about fitting the heat exchange to the xe...
Apart from the 'I did it first' award, I don't really see the point? Unless of course space is a premium...
Phil GTE
22-09-13, 09:03 PM
Good to hear some Nova work is going on Johnny.
I remember SEF with the double radiator set up.
Also remeber one of the saloons (grey one?) towing my GTE, possibly at the RB rolling road in Walsaw. Good times.
Johnny A
22-09-13, 09:42 PM
Hey Phil, yeah that rad setup was comedy lol I can't say I remember towing you with the grey saloon - TBH considering how rusty it was I am surprised it didn't tear in half!
Update:
After moving the shell (which is quite hard when both front hubs are off at Harry Hockley motorsport being converted) I stripped the front end and got to work. I chopped off the N/S front mount brackets and popped the engine in the bay, I am making most of the mounts but I have a phase 2 corsa-b O/S front mount to cut up for parts.
The gearbox was a bit of an ****, the shifter arms that the cables connect to foul the chassis rail. So after some chopping I got the engine to sit correctly but I only managed to cook up the O/S engine mount before running out of time. The rest is held up with wood blocks until next weekend.
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash4/1236607_10153226551290214_964136656_n.jpg
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn1/q71/s720x720/1236876_10153226551280214_1578326108_n.jpg
This is the N/S mount, similar to the F28 one basically. It's not actually fitted... it's wedged in place lol
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/q77/s720x720/1236571_10153226551245214_634475626_n.jpg
It's be a bit tight back there:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/q73/s720x720/555827_10153226551570214_1894956809_n.jpg
Is that GB mount not a bit far forward?
maddogdaz666
24-09-13, 12:20 AM
Does that mean your gonna have to move the brake servo to fit the F23 and cable linkage?
Is that F23 from a Vectra or astra?
Johnny A
25-09-13, 10:01 PM
Is that GB mount not a bit far forward?
It's not fixed, it's wedged
Johnny A
25-09-13, 10:01 PM
Does that mean your gonna have to move the brake servo to fit the F23 and cable linkage?
Nah there is room
Johnny A
25-09-13, 10:01 PM
Is that F23 from a Vectra or astra?
Astra-G Z20LET one
Johnny A
29-09-13, 08:55 PM
Update:
Only a days work done today as I was playing Airsoft on Saturday.
I managed to get the engine sitting nicely on all it's own engine mounts:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn2/1381794_10153249802915214_1829336811_n.jpg
front gearbox mount:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/602941_10153249801875214_1256769930_n.jpg
https://scontent-b-vie.xx.fbcdn.net/hphotos-frc3/1379746_10153249800740214_164198853_n.jpg
https://scontent-a-vie.xx.fbcdn.net/hphotos-ash3/1234544_10153249802010214_993027776_n.jpg
With the front mounts done I jacked the rear of the box up until the back of the box was almost kissing the rack gaiter:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-frc1/578019_10153249801085214_1694491268_n.jpg
Cooked up the basic rear mount:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/554143_10153249804175214_1580728324_n.jpg
Obviously all 3 mounts need bracing and cleaning up but for now this will do.
Next I wanted to see how bad the shift cable length situation was
Don't need this but there is something wrong with cutting good metal out of a Nova:
https://scontent-b-vie.xx.fbcdn.net/hphotos-prn2/1375988_10153249802345214_733670068_n.jpg
I made a hole in the very top front of the tunnel and popped the cables in place:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn2/1173775_10153249803125214_1626449344_n.jpg
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-prn2/1375310_10153249804000214_1354373979_n.jpg
Tight but clears:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-frc3/1376505_10153249803150214_599761632_n.jpg
Removed the factory shifter metal, welded the plate up and added some mounts for the shifter:
https://scontent-a-vie.xx.fbcdn.net/hphotos-ash3/1383760_10153249804905214_1511032153_n.jpg
Bolted up, cable length isn't too bad at all!
https://scontent-b-vie.xx.fbcdn.net/hphotos-ash4/1235107_10153249804950214_1098123570_n.jpg
and finally a bit of porn:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn2/1378247_10153249801060214_1398948808_n.jpg
Nice work, does it change gears ok then? Love the coilovers.
Johnny A
29-09-13, 09:44 PM
Selects fine but I have fitted the spare old cables I had lying about for now and they are all gummed up, will fit the good ones when I do final fitting.
The coilovers are rather sexy, probably wasted on this car but never mind.
The Simps
29-09-13, 09:47 PM
You're working on the wrong car mate ;)
Johnny A
29-09-13, 09:55 PM
You're working on the wrong car mate ;)
https://scontent-a-cdg.xx.fbcdn.net/hphotos-ash3/1375259_10153250068575214_157044530_n.jpg
Johnny A
05-10-13, 10:30 PM
Bit of work today
The Harry Hockley motorsport hubs turned up yesterday which meant I could put the car on it's wheels and move it
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-frc3/1378776_10153271201465214_1795030942_n.jpg
With the car in a better position in the unit, I removed the engine and trimmed the N/S/F engine mount bracket:
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn2/1383047_10153271188795214_1901722575_n.jpg
I swapped the original Calibra C20XE half shaft for a Z20LET one, I would like to make out I did it because it's stronger etc... but it was purely because the C20XE half shaft bearing was worn a bit ;)
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn1/68607_10153271201155214_1140469930_n.jpg
Pimpin' ICV relocation:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-frc3/1380621_10153271200580214_1619411796_n.jpg
I decided to go with a conventional alternator setup seeing as the car isn't for me anymore, instead of taking a sledge hammer to the chassis rail like I did on the original car I went all fancy:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/1376504_10153271202340214_1495600295_n.jpg
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash3/575657_10153271202840214_1469829274_n.jpg
As shot of the home brew engine mounts, they still need bracing and cleaning up:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-ash4/1385934_10153271203805214_747442948_n.jpg
A bit of artwork from Ben @ TTV racing, real shame no one will actually get to see the thing:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-frc3/1390617_10153271203545214_182954543_n.jpg
I wanted to check that the chassis rail work was sufficient to clear the alternator and also some tweaks I made to the N/S chassis rail for the gearbox so I popped the engine back in to see:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn1/644213_10153271203900214_1380861642_n.jpg
Just enough clearance! I can't say the same about the bottom pulley though:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn1/993707_10153271204405214_626697126_n.jpg
That's that scratched then! Obviously the engine sits over a few mm more than off the shelf kits offer but it was nessesary for the gearbox to clear the N/S chassis rail
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-prn1/946410_10153271204545214_1605522785_n.jpg
nova_stee
06-10-13, 09:24 AM
Would it not of made more sense putting a notch in the bottem of the nearside leg instead of having the engine over one way causing the nearside inner cv boot to be streched for length and the offside being squashed up?
And your probly going to have to nothch the offside leg now for the pullys.
not critasicing just mentioning it
Johnny A
06-10-13, 09:08 PM
Would it not of made more sense putting a notch in the bottem of the nearside leg instead of having the engine over one way causing the nearside inner cv boot to be streched for length and the offside being squashed up?
And your probly going to have to nothch the offside leg now for the pullys.
not critasicing just mentioning it
It's only 2mm compared to the original but as you will see the N/S chassis rail is already notched for the super sized gearbox.
Update:
N/S chassis all plated up:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash4/1374132_10153275004245214_1996152065_n.jpg
https://scontent-a-lhr.xx.fbcdn.net/hphotos-ash3/1384310_10153275004050214_1104802825_n.jpg
O/S rail all plated up and painted (inc the notch for the bottom pulley)
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn2/1391516_10153275003900214_2133821595_n.jpg
N/S all painted:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/960014_10153275004790214_141033509_n.jpg
Johnny A
13-10-13, 01:22 PM
Update:
More chopping and welding and the original shifter rod hole is adapted to carry the shifter cables:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash4/1380568_10153297634295214_609123503_n.jpg
https://scontent-b-lhr.xx.fbcdn.net/hphotos-frc3/1380114_10153297634385214_1413732447_n.jpg
Steering rack gets a corsa-b rack mount and some modded poly rubbers:
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/1374738_10153297634595214_1249718462_n.jpg
With the chassis rails and the bulkhead done I popped the engine back in to check everything fitted (getting good at this now):
The shifter cable angle here is perfect:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/1381742_10153286089230214_163352642_n.jpg
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn2/1378534_10153286089940214_831006317_n.jpg
Not ideal inside though:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/1375660_10153286089170214_1699228736_n.jpg
Engine back out and some painting:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-ash3/1383672_10153297634780214_875626127_n.jpg
Nice clear tunnel for the exhaust:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/563674_10153297635030214_820939442_n.jpg
https://scontent-b-lhr.xx.fbcdn.net/hphotos-ash4/1393432_10153297635235214_460460447_n.jpg
Using a Shultz gun with waxoil canisters (got the gun and 6 canisters for £30 delivered!) I filled all the cavities in the forward part of the chassis - no pictures but it got a little messy to say the least!!
Because I am using eccentric top mounts I needed to enlarge the top mount centre hole:
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn2/1385510_10153297634795214_1380849912_n.jpg
Strengthening plates welded on and suspension test fitted:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn2/1234821_10153297371375214_824798643_n.jpg
https://scontent-b-lhr.xx.fbcdn.net/hphotos-ash4/1390596_10153297371270214_2086895880_n.jpg
Painted:
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn1/1381954_10153297369940214_567377104_n.jpg
Grinder attacked, the chunk that flew off cracked me in the gut too:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn2/1392926_10153297371170214_211034590_n.jpg
Johnny A
13-10-13, 01:22 PM
I started to work on the rear brake lines, running rear discs (Corsa-C SRi gear waiting to be fitted) meant I needed an adjustable bias valve to reduce the pressure on those brakes. I removed the factory bias valves and removed their internals, I then joined the two rear lines together (yes before anyone says it I have by doing so removed the factory dual circuit) so I can run a single line to the rear of the car:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-ash3/29539_10153297370390214_1190571681_n.jpg
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn2/1386009_10153297370530214_1216903616_n.jpg
I reinstalled part of the tunnel's upper plate whatever you call it, reason being it will hold the carpet's shape, offer mounting for the bottom of the dash, centre console and the bias valve:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash4/1390544_10153297370725214_813088108_n.jpg
Next up was the pedal box, I needed to mod it to take a hydraulic master cylinder:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-ash3/1376588_10153297370930214_418206368_n.jpg
https://scontent-b-lhr.xx.fbcdn.net/hphotos-ash4/1385727_10153297370830214_1864794281_n.jpg
I modded the original clutch cable hole:
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/1391904_10153297370265214_996400036_n.jpg
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn2/1395251_10153297370080214_1920782278_n.jpg
I fitted a Corsa-B epas column, surprisingly it almost fits! It bolts up to the front bracket fine but I had to take a hammer to the upper bulkhead a bit so the motor doesn't rub against it. I then cooked up a rear bracket:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/1390705_10153297369810214_1093568800_n.jpg
Fantastic work John, nice way to run one line for the rear brakes. Love what you've done with the shifter cables too.
gary_126
13-10-13, 09:07 PM
Great work, the cable shift looks to be working out well.
Johnny A
13-10-13, 09:49 PM
Cheers guys, the cables inside the cabin can be straightened up I just need to modify the shifter casing.
Today all I really did was paint stuff, gave the engine bay the once over, painted the modified pedal box and corsa-b rack mount, waxoiled the N/S/F arch, cleaned and built up the steering rack (Corsa-B epas rack) using the Nova track control arms.
The Simps
13-10-13, 11:18 PM
Liking the fast progress on this, means you'll be back on the rwd one soon!
Some nice/ideas touches going into this too.
gary_126
26-10-13, 10:28 PM
Are the nova track rods not a different fitment? (male instead of female or vice versa)? Ive the same setup for when I eventually start on the merit.
nova track rod ends are the same as pre 98 corsa b's and corsa c's
Novasport
26-10-13, 11:36 PM
They are on about the track rod arms, not the track rod ends. The arms on a Nova are shorter than a Corsa B as they have a narrower track
gary_126
28-10-13, 04:06 AM
Yes the arms is what i was on about, where they connect to the rack (i was sure the nova and corsa ones were opposite fitments, but ive yet to strip both racks to check.) my plan was shorten and re-thread the outer ends of the corsa arms so there nova length.
Why use Corsa stuff at all Gary?
Making some good progress on that aren't you. You think the adjustable bias valve will be enough to bias out the rear discs? I'll be fitting my C rear setup soon and was expecting to need an inline bias valve but I already have a Wilwood adjuster plumbed in so if that's sufficient then all is well.
Cable shifter mods look excellent too
Johnny A
28-10-13, 07:03 PM
Making some good progress on that aren't you. You think the adjustable bias valve will be enough to bias out the rear discs? I'll be fitting my C rear setup soon and was expecting to need an inline bias valve but I already have a Wilwood adjuster plumbed in so if that's sufficient then all is well.
Cable shifter mods look excellent too
Cheers, the bias valve will certainly handle the amount of bias needed. IIRC it goes from 100% all the way down to about 10% and the factory ones are 35-40% depending on model so no worries there.
Little update:
Corsa-B EPAS steering setup and modded pedal box all bolted up:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn1/1378735_10153344067170214_1323970468_n.jpg
Hydraulic feed line to the clutch master cylinder:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash4/1012716_10153344067775214_1788433885_n.jpg
Engine mounts strengthened, painted and engine fitted :)
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-frc3/1380196_10153344067470214_693558272_n.jpg
Hydraulic clutch pressure line connects up perfectly:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn2/1395186_10153344068010214_2098754566_n.jpg
Love the cable shift, really tempted to go that way with mine now
Johnny A
03-11-13, 09:52 PM
Update:
Been a messy weekend, I really do hate CV joint grease!!
Strut tops in place:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-ash3/1455079_10153381298755214_750504604_n.jpg
Bolting up the suspension components:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-ash4/1459740_10153381299895214_758364965_n.jpg
The N/S is completely bolted up and with the coilovers in place but without springs I simulated different ride heights:
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-prn2/1452201_10153381300660214_1053402440_n.jpg
Lotus discs come out of their boxes, didn't order drilled ones but meh:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn2/1380245_10153381300480214_1102093659_n.jpg
Discs and wheels bolted on, I do need spigot rings made up - does anyone know where I could get some cooked up??
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-prn2/1385966_10153381299025214_1658387181_n.jpg
Being a tart the first thing I did was take it to the extreme:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn2/1451415_10153381297650214_1568832203_n.jpg
Not that this would work as the shocker is maxed out:
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash3/945983_10153381297815214_1415501711_n.jpg
front control arm clears the gearbox ok:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash4/1380256_10153381298035214_141624095_n.jpg
Even with the stupid driveshaft angles it clears the chassis rail with room to spare:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn2/1384077_10153381298210214_568830750_n.jpg
Fruity camber:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn1/6446_10153381298375214_1615331113_n.jpg
At 50% of the shocker's travel the ride height is respectable:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash3/994572_10153381300270214_571693586_n.jpg
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-frc3/1450190_10153381299610214_985206172_n.jpg
The driveshaft angle is perfectly flat, wishbone and steering arms are spot on too:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn1/537976_10153381299385214_1267151029_n.jpg
The coolant pipes are coming along:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/1457497_10153381298605214_1865475869_n.jpg
Due to the gearbox front mount the Nova bottom coolant pipe fouls, the original XE calibra one is a perfect fit (I will buy a silicone version in due course):
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn1/994044_10153381300890214_76400827_n.jpg
The Simps
03-11-13, 10:10 PM
Coming along mate
Looks great so low... lol nice work getting the shaft straight. All very good work.
Johnny A
03-11-13, 10:58 PM
Looks great so low... lol nice work getting the shaft straight. All very good work.
Cheers Ben, I did hear you have a dodgy angle on your shaft :d
gary_126
10-11-13, 11:28 PM
Looking good! Will the colum suit a std dash?
Johnny A
13-11-13, 08:44 PM
Looking good! Will the colum suit a std dash?
yes, when done you won't know the difference.
Update:
I have built all the coolant pipes up, it's pretty mental and tight but everything clears fine:
Servo vacuum line all made up and fitted, also the ICV relocation gets a bracket to hold it securely in place (I used a modified secondary water pump holder from a Z20LET):
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn2/1422391_10153414187885214_510486596_n.jpg
Then the heater matrix return hose goes on:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash3/1454944_10153414185355214_1680730222_n.jpg
Then the heater matrix feed completes silicone valley:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash4/1458525_10153414185085214_181223329_n.jpg
It's the details, a p-clip to hold the hydraulic clutch line in place:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn2/1468650_10153414188460214_1386969803_n.jpg
New fuel lines using plastic and marine grade rubber:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash4/1394354_10153414185595214_1986949654_n.jpg
Intake hose:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-frc3/1426358_10153414188230214_334117904_n.jpg
The Simps
15-11-13, 12:07 AM
Good work bud, looking tidy.
Johnny A
17-11-13, 10:20 PM
Update:
The Leda coilovers are designed to be left unpainted, however these had developed little rust 'blisters' on the body so I decided to put some paint on them:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/1463090_10153441790215214_1837777655_n.jpg
Bolted up:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn2/1475914_10153441790165214_838594525_n.jpg
I am running Cally turbo front brakes and am using Lotus Elise front discs which offer almost identical dimensions and the same stud pattern. In fact the only real difference is the centre bore which is 60mm as opposed to the Nova's 56.6mm. A quick nose on egay found alloy wheel centre bore adaptors from 56.6 to 60.1mm, simply pop directly onto hub:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn2/1455190_10153441790815214_362632357_n.jpg
Then disc pops over them:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/1458544_10153441790845214_218476148_n.jpg
Calipers were stripped and painted, still need to order some pads. It's a road car that won't see the track so want pads that offer high initial bite, any suggestions??
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-frc3/1452420_10153441791525214_1194686268_n.jpg
Not happy about the wheel weights on this alloy - I checked myself it's not buckled at all so I can only theorise the tyre is to blame??
I got all excited about putting her on her feet for the first time, after I set up the ride height and tracking I got the height I wanted:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash3/1455983_10153441790850214_508056624_n.jpg
No idea on drop, 60mm maybe???
Anyway check out the driveshaft angle:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-frc1/1012470_10153441791375214_184452258_n.jpg
I love it when a plan comes together!
Thanks to the top mounts and the adjustable camber on the coilovers I got a healthy clearance between the tyre and the spring seat:
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/1460025_10153441791730214_631796356_n.jpg
At this point the only annoyance is the steering lock, the tyres rub on the inner arches/gearbox end plate. The only two solutions I can think of are to weld up the last tooth at each end of the steering rack (means a lot of hassle removing and rebuilding the rack) or make some sort of lock-stops like the carltons run.
Have you got a link for them spigot ring things dude?
Johnny A
18-11-13, 04:07 AM
Not whilst on my phone no, it came up easy enough in an egay search though.
I've got metal spiggots before too off eBay although they were about a tenner a pair.
Mintex 1144 would be my choice for road brake pads.
All looking good sir nice work.
Why do the coilovers have such a big top hole? Nice straight shaft you have too. Are the discs not on the wrong way? For the lines of drilled holes?
I run Mintex m1144s as well. Great pad.
The Simps
18-11-13, 01:30 PM
Large top hole is for camber adjustment Benn I would guess.
I thought that, but it's not slotted as i'd of expected.
Johnny A
18-11-13, 06:36 PM
Why do the coilovers have such a big top hole? Nice straight shaft you have too. Are the discs not on the wrong way? For the lines of drilled holes?
Ben if you look in the images of the coilovers fitted on the car you can see the off-centre camber adjusters, that's why the top hole is bigger. The bottom hole is slightly elongated vertically.
I thought you would like the driveshaft angle lol as for the discs I bought a pair and they were listed as being solid not drilled. Being drilled they would need to be handed, well they sent 2x O/S ones. I don't really care it won't effect performance at the level they will be used, to be fair they are a little overkill.
Ah ok and yeah that is a nice angle, but with a bit of play mine arnt that bad now..lol And oh, thats a bit gay. Went i bought some the paton was the same but its works right on both sides...Either way, its just me being picking. Loving the work so far.
Johnny A
24-11-13, 10:13 PM
Updatings!!
First off lets start with some pimpin' blue seat belts:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/7039_10153470457935214_898481107_n.jpg
O/S wing being prepped, aerial hole welded up and the rough areas painted with rustoleum which is much better than hammerite:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/1458643_10153470458425214_1587749310_n.jpg
The height of the engine was causing issues with the standard throttle cable route so I opted for this:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash4/1463957_10153470458720214_1692741759_n.jpg
The next thing I wanted to look at was the relationship the EPAS motor would have with the Mk2 fuse box as there have been concerns on this thread:
http://www.pngclub.com/forum/showthread.php?204076-Corsa-Epas-in-to-a-mk2
in addition in this thread it has been mentioned that although the Nova ignition barrel does fit it's at the wrong angle for the Nova column shroud to fit.
Upon bolting the dash in I was confronted by a bigger issue, the epas column is angled too high so instead of coming out of the middle it is touching the top of the column hole:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/936015_10153470459565214_945703460_n.jpg
Although at this stage the interaction between the epas motor and the fuse box would be minimal, however the relays normally attached to the fuse box will need relocating:
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/1395160_10153470459990214_920639640_n.jpg
Armed with a brain high on monster energy drink I devised a solution that would correct the column angle and also relocate the ignition barrel so the shroud fits!
The Corsa epas column front section has 3 bolts that attach it to the drive section, I removed the front section and compared it to the Nova's original outer casing:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/1471867_10153470460705214_148822628_n.jpg
Here you can see the mounting plates for the car was in the same position on both columns, however when turned on their side the bracket itself has a height difference:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash4/1478977_10153470461420214_1900471322_n.jpg
This shows why the column sits high!
With the epas column front section removed I am left with this:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn2/1462846_10153470461440214_947714394_n.jpg
Anyway to correct both the column height issue and the ignition barrel angle the solution is pretty obvious - make a hybrid of the Nova and Corsa columns.
Chop Nova column just as the collapsible section starts:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn2/1450725_10153470462060214_1043034884_n.jpg
Chop the end off the the Corsa column:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn2/1472920_10153470462890214_1790077710_n.jpg
The two sections ready to be welded:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-frc1/579160_10153470462905214_1722532953_n.jpg
I turned the welder up to 'So you want to play a game' power level and let rip, I had to be careful that I had the angle straight and also the 3 bolt flange seems to be off-centre:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn2/1469939_10153470463335214_1953903260_n.jpg
I bolted it all together and it all lines up perfectly!! The dash, shroud and ignition barrel all look factory now :)
The Simps
24-11-13, 10:24 PM
Smart Jonny boy
TB cable is best run that way, looks much much more tidy. Thanks for all the Epas info!
Johnny A
25-11-13, 08:25 PM
Yeah the throttle pedal is still nice and smooth, the cable is only about 5 years old which helps.
No worries on the epas info, today I spent an hour up the unit so I take a few pics of the modded parts bolted up:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash4/1424354_10153474543725214_1405842849_n.jpg
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn2/1463932_10153474543910214_1914822569_n.jpg
Being paranoid about anything sold to me through ebay I decided to test the epas column to see if it worked:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn2/1424390_10153474543925214_1645490997_n.jpg
A total bodge as you can see, the wiring is too thin and all the wires are just twisted together... still better than some installations i've seen though lol
It works! I only went to 50% power to prevent overload of the wiring but even at 50% I can grab the steering hub and turn the wheel with two semi-flat tyres!
scott.parker
25-11-13, 08:51 PM
That's an awesome solution dude, loads have fitted it with it through the dash! :)
Johnny A
25-11-13, 09:08 PM
How do you mean Scott?
Johnny A
25-11-13, 09:52 PM
Saw your original post ben lol, I will try and fit the fuse box on saturday for you
lol Yea i forgot. Then i went back and read it all again. As you said the box does but the relays don't...
Johnny A
01-12-13, 09:39 PM
Update:
This weekend i continued work on on the corsa epas column and hit a major snag :(
First off I wanted to see if the fuse box actually cleared the epas motor, I cut off the mounts at the back that hold the relays in place. The box fitted fine, in fact it cleared it with plenty of room! The wiring out the back touched the motor a bit but it's not tight against it, here it is attached to the dash:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/1460169_10153498357480214_1862008837_n.jpg
With dash bolted in:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn2/1471386_10153498357365214_81675825_n.jpg
As you can see there is plenty of room, I have no idea how others have fitted their to warrant moving the fuse box :confused:
Cheeky random pic of the radiator fan, I do like Kenlowe fans:
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-frc3/1479312_10153498357875214_1973501780_n.jpg
Feeling chuffed with myself I decided to fit everything including the drivers seat for final testing.... and hit that snag. The steering lock will not engage and also when bolted up tight the wheel boss indicator cancelling metal lug thingy rubs badly against the plastic column end thingy. Technical stuff!
It was a real ballache, I started off fixing the steering boss issue. The central rod needed to protrude out of the end about 5mm more but I couldn't retract the outer column sleeve as it would push everything back (shroud, ignition barrel) so they wouldn't clear the dash :(
In fact the only way to get the extra centre rod length is to keep the front section outer sleeve in the same position and move the drive section forward 5mm. I had to cut the forward section away from the 3-bolt flange and shave a section out for adjustment, you can see a small gap near the flange - at this stage the front section is 'free floating' from the flange to allow for adjustment:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/1460082_10153498358745214_1597004640_n.jpg
The rear mount was loosened to allow for movement and I positioned the motor using wood and whatever else I could find, I did take this opportunity to twist the drive section to pivot the motor upward a little giving even more fuse box clearance :thumb:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn2/1450854_10153498358240214_1146096992_n.jpg
Then I slid the drive section forward until the boss synced up with the plastic section at the front of the column:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn2/1422522_10153498358305214_464574866_n.jpg
Problem sorted!! A nice fit all round:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/1002042_10153498358930214_132513954_n.jpg
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn2/1471312_10153498359105214_1139961680_n.jpg
Next up was the steering lock, it works by having a spring loaded pin that locked into a hole on the centre rod. The hole was too far forward and moving the rod/drive section forward has only made it worse. Here is what I had to deal with:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash3/67958_10153498358510214_638129096_n.jpg
The only saving grace is that the section with the hole is twice as thick and is a kind of sleeve that is welded at one end, so it was simply a case of grinding off the welds and moving the sleeve down :)
Johnny A
01-12-13, 09:39 PM
I remove the whole assembly and separated the drive section from the front, here you can clearly see the thicker section that houses the hole:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash3/62337_10153498359565214_1587267188_n.jpg
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn2/1426128_10153498359615214_1559730738_n.jpg
Easy... simply grind down the weld at the front end and slide it down the shaft.... well no :tard:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-frc3/1480684_10153498359860214_1451855819_n.jpg
It turns out this is a compression section of the centre rod and the thicker outer sleeve is a bridge between the two outer rods :mad:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-frc3/1450207_10153498360155214_62555063_n.jpg
Feeling like a bit of a dick for not realising beforehand a solution wasn't too far away... assuming I wasn't being a heavy handed oaf today.. which I was :wtf:
First up I tapped the thicker sleeve down the bottom rod till the holes lined up:
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash3/1479037_10153498360195214_1693492008_n.jpg
I then grabbed the old Nova centre rod out of it's column and chopped the end of:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn2/1486776_10153498360755214_1002678010_n.jpg
I milled it down till it was a tight fit into the corsa's thick sleeve.... in fact a special blend of 'I can't be arsed to mill this down a little more' and 'I will use a bigger hammer' killed the threads on the Nova's front rod.... :tosser::wall:
Feeling pretty **** about the whole thing and with a few hours left I fitted what was left of the epas column into the car again and cooked up a crude mount for the Epas brain box:
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/1422515_10153498360910214_467978919_n.jpg
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn2/1457630_10153498361000214_1363034360_n.jpg
It bolts to the underside directly behind the motor, it's a bit tight under there but it does fit and won't be seen once the dash is in place :d
The Simps
02-12-13, 12:19 AM
I hope this mod is worth it! Could of had your rwd one finished by now.... :p
Christ, that's a hell of a read. I might start re thinking going Epas..lol
Johnny A
02-12-13, 07:28 PM
I hope this mod is worth it! Could of had your rwd one finished by now.... :p
Oh shut up you tart lol
Johnny A
02-12-13, 07:29 PM
Christ, that's a hell of a read. I might start re thinking going Epas..lol
Mate seriously I am giving you gold here so you don't make the same mistakes I have, if I had to move the hole for the steering lock pin I'd have just machined the existing hole longer (towards the column hole) instead of what I did
gary_126
02-12-13, 10:39 PM
Bad times! Defo not a straight forward conversion as some say, but where theres a will, theres a way. I finally got a column but its missing the ecu, so ill have to see if there interchangeable.
Mate seriously I am giving you gold here so you don't make the same mistakes I have, if I had to move the hole for the steering lock pin I'd have just machined the existing hole longer (towards the column hole) instead of what I did
Oh i know, i can't thank you enough.
Machine the hole looks like an easier way to do things.
Johnny A
10-12-13, 09:25 PM
Update:
Progress is slow thanks to Xmas meals, the cold weather and general laziness.
I have been working on the wiring both in the engine bay and cabin, I popped on the XE's loom and set about moving the bulkhead grommet to match the Nova... I really hate the blue tack stuff found here :roll:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn2/1465137_10153533508815214_698947689_n.jpg
The +ive feed and ron plug off the XE loom is way way too long so it gets shortened down and heat shrinked up:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn2/1463927_10153533508780214_1905077236_n.jpg
Problem: The previous owner (or owner before that) intended to convert to XE power so cut a hole in the bulkhead already... using a fisher price 'my first power drill'... I also use the term 'hole' rather loosely as it was shape not known to this world as yet:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn2/1476436_10153533509585214_593936752_n.jpg
The grommet didn't sit well at all and had no chance of sealing so it was chopped out and a new bit of metal welded in with something resembling a round hole:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-ash4/1471865_10153533509660214_1515138432_n.jpg
As you can see a weld repair has already been done here, it's not too bad so I haven't touched it. All the paint and sealant has been removed to check for rust pixies, I then put down a layer of Rustoleum:
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn2/1483025_10153533509485214_589419110_n.jpg
Take that RUST PIXIES
https://scontent-b-lhr.xx.fbcdn.net/hphotos-ash4/1454914_10153533510035214_1092087139_n.jpg
I repaired the chassis loom inside the bay, for some reason the previous owner had been messing with it. I also added a 2nd main power feed into this loom to power the EPAS
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/1463506_10153533508905214_1088729047_n.jpg
Last of the silicone pipes arrived, here using a OEM-sized Calibra C20XE bottom rad hose. It's a perfect fit, if you're wondering why remember my engine sits higher than normal.
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash4/1459853_10153533509970214_261794718_n.jpg
Loving your work John, very impressed you cut out and welded back the loom hole too.
Johnny A
15-12-13, 10:06 PM
Small update:
Thanks to a tasty Xmas meal I've had a dodgy gut for the whole weekend so progress has been slow :(
I tidied up the bay wiring today and connected up the engine:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn1/1521763_10153552721170214_457982343_n.jpg
I decided to install an early Mk1 wiper motor as they look much better than the later 'econo-spec' model:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/1390505_10153552721090214_2055753828_n.jpg
With the bay wiring almost done I have two main power feeds that go into the cabin, one being the factory original and one designated to power the epas column:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-frc3/1483340_10153552721190214_694160300_n.jpg
I didn't like how the factory main feed isn't fused at the battery so along with the epas feed they both get a 50amp maxi fuse:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/1525002_10153552721845214_287661684_n.jpg
A slightly modded brake fluid reservoir with a take off for the hydraulic clutch setup:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn1/1521210_10153552721715214_991878523_n.jpg
Johnny A
15-12-13, 10:06 PM
Small update:
Thanks to a tasty Xmas meal I've had a dodgy gut for the whole weekend so progress has been slow :(
I tidied up the bay wiring today and connected up the engine:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn1/1521763_10153552721170214_457982343_n.jpg
I decided to install an early Mk1 wiper motor as they look much better than the later 'econo-spec' model:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/1390505_10153552721090214_2055753828_n.jpg
With the bay wiring almost done I have two main power feeds that go into the cabin, one being the factory original and one designated to power the epas column:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-frc3/1483340_10153552721190214_694160300_n.jpg
I didn't like how the factory main feed isn't fused at the battery so along with the epas feed they both get a 50amp maxi fuse:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/1525002_10153552721845214_287661684_n.jpg
A slightly modded brake fluid reservoir with a take off for the hydraulic clutch setup:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn1/1521210_10153552721715214_991878523_n.jpg
The Simps
15-12-13, 10:29 PM
Soon be running bud! Is this car to be for your mum to drive?
Johnny A
15-12-13, 10:38 PM
Yep and I am happy to build it for her... although I will be "borrowing" it and will bring it to some shows
Johnny A
22-12-13, 11:14 PM
Engine wiring all done bar the coolant fan - looking almost complete now:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-frc3/1476446_10153576520745214_1930652165_n.jpg
Revised primary power feeds with a 50amp maxi fuse each:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-frc3/1525428_10153576520830214_1274574037_n.jpg
Cabin loom is getting there too:
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn2/1512726_10153576520650214_1695271055_n.jpg
I am converting all the dash illumination to white and blue LEDs, I am going all out on the fan/heater controls with white backlighting and blue control knobs:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn2/1480726_10153576521000214_1851417392_n.jpg
Looking good John, i do love that this will be your mum's ride.
Johnny A
25-12-13, 06:20 PM
More work on the white backlighting for the heater controls, in total 12 surface mount 120 degree angle LED's are used in the rear housing. 11 LED's are general backlighting which are strategically placed to give perfectly even illumination (which is actually really difficult due to the housing shape causing shadows/dark points), the 12'th LED (most central LED on a little stand) is solely for the rear heated screen and gives a dim glow normally and a bright glow when the knob is pulled out to turn the screen on.
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn1/563621_10153586256400214_954004846_n.jpg
off:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-ash3/1538759_10153586255835214_654365330_n.jpg
I like what you've done. I LED lit mine years ago and dew to the lack of light removed them. So adding in the extra should be great.
scott.parker
27-12-13, 10:36 AM
Everyone called me a chav when i put leds in my old dash lol
Johnny A
28-12-13, 11:12 PM
Put a Burberry baseball cap on Scott and you pretty much are a chav lol
Update:
The interior colour scheme is black GSi with calibra front leather seats from the donor, but GSi parts are a rip off so I decided to do what I did on the original SEF shell and spray trims with Halfords flexible vinyl paint. So far the dash, fusebox panel, rear hatch panel (early mk1 plastic) and both rear 1/4 cards are all painted up.
I was going to get on with wiring (simply because I can hide inside the car itself with a small heater :D) but I left the soldering gear at home, so instead I decided to build the exhaust downpipe. It turned out to be more work than expected, the part that bolts to the head sandwiches between the radiator and exhaust studs so I had to move the radiator forward.
This is a picture of the slam panel taken from the engine-side, I drilled the spot welds out, ground back the area and rewelded the bracket back on:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn2/1545133_10153597538195214_1149011477_n.jpg
Pic from underneath:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn2/1545721_10153597538510214_269377150_n.jpg
Same again for the other side:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn1/1512529_10153597538610214_1193089097_n.jpg
This moves the top of the radiator back about 1 inch, might not sound like enough but it's enough to allow a smooth fitment of the exhaust downpipe and plenty of clearance when it's bolted up :D
I moved onto the exhaust downpipe, I didn't like how low it hangs as it passes under the sump. I cut 1 inch out of the secondary pipes for a nice tight fit under the sump:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn1/1524935_10153597538790214_832108250_n.jpg
thedjse
29-12-13, 08:47 AM
Just read full thread awesome projects pal :)
I absolutly love this its going tobe one heck of a car keep at it.
Rick
Johnny A
29-12-13, 08:53 PM
Cheers guys for the comments :)
Today doesn't show any pics because it was all boring wiring, lots of relocating due to the epas though - luckily I have a scrapper Carlton GSi in the unit which is perfect for little spares like bolts, wiring spares, grommets etc...
Epas main wiring, epas ECU, aftermarket controller all wired up
Cat1 alarm bolted to bulkhead and 3 immobiliser circuits wired up (only 300 more wires to go then lol)
New relay position located and suitable relay bracket/holder lifted from Carlton, modded to suit and bolted up
Wiring left to do:
Remaining alarm wiring (including central locking using two aftermarket soleniod and boot release soleniod)
Heated seat harness (Calibra front seats)
Electric window harness (I have a complete harness lifted from a GSi but it's been butchered a bit)
Digi dash plug change and harness from rear discs (ABS pickup - 12v signal amplifier - Pulse converter - Digidash)
Sound system harness (3-way components up front, 2-way co-axials in rear factory positions but as this was a base model there is no wiring to rears yet)
Additional boot light wiring into tailgate (downlit LED's built into tailgate interior panel)
gary_126
30-12-13, 09:27 PM
cant wait to see this car done :D
Johnny A
05-01-14, 09:17 PM
Constant soldering makes Johnny a dull boy :(
Not much to report as it's all wiring! I have got about 80% of the alarm wiring harness spliced into the Nova's loom and relocated the 4 relays that would normally attach to the back of the fuse box.
Starting to look more complete, notice the alarm box on the far left (with all the dash in it's going to be near enough impossible for a thief to try and remove that!) and also the far right notice the separated relay bundle on it's own bracket:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/1555448_10153626098210214_1709441076_n.jpg
https://scontent-b-lhr.xx.fbcdn.net/hphotos-frc3/1545853_10153626097830214_1595071228_n.jpg
Relay block disappeared?
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-frc3/1545660_10153626098005214_206295634_n.jpg
Nope it lives on the underneath of the battery tray now:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/1463891_10153626098370214_1154910713_n.jpg
It's getting really cluttered now, running out of room for things:
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/t1/1601247_10153626098505214_1654215484_n.jpg
Looking good John, If you'll be using the side air vents on the dash, wont the alarm box be in the way? Mine is a lil back from that and the air ducting wont go in fully pushing the vent out. very annoying.
If the Epas all sorted now?
Johnny A
06-01-14, 04:00 PM
If it doesn't fit I will modify it, I know I have to make a custom on for the drivers side because of the epas anyway.
Epas is all fixed now, I tested it yesterday and its working perfectly :)
The Simps
06-01-14, 04:16 PM
Good work mate, almost there!
Johnny A
22-01-14, 10:11 PM
Little update: Not much has been done on the XE Nova over recent weeks due to work being done on my Carlton estate. I have been working on smaller parts at home like colour coding the digital dash to blue and white:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn1/t1/154471_10153671203690214_922813343_n.jpg
It uses modified colour films and LED lighting to achieve this, it's a pretty complex job and the LCD plates are delicate but I love the outcome! I wrote a comprehensive guide on doing this modification in the 'how to' section so check it out. I have also had requests for me to modify other people's dashes to this setup, I will do this with a 1 week turnaround but due to the costs of materials and the time involved £45 with return postage is the cost, so please only contact me if you want the work carried out.
Now for a bit of a curveball! Some of you know I have a right shed of a pug 106 diesel I use for work, it kicks back 60mpg all the time which I love. Trouble is it won't pass another MOT without money being thrown at it and TBH it's not worth it. In addition to this my awesome and crazy Carlton estate Z20LET will be up for sale this year :(
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn1/944729_10152847680415214_68126904_n.jpg
With these two going I was brainstorming about a car that will combine some of the attributes of both cars - namely do 60mpg, look ace, cheap tax, offer massive boot space for getting rid of those pesky dead bodies.... aaaand cheap to insure.
Tall order but I found a solution, it involved asked a guy with long hippy hair a few choice questions and throwing money him but after a short discussion I acquired a Nova all of PNG are very familiar with:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-frc3/t1/1531850_10153684445300214_483949635_n.jpg
Plans for this badboy are:
1.5TD Isuzu engine (I am in need of one if anyone has a complete one??)
Associated mods to engine to bump up the power and economy (FMIC, exhaust, direct air feed and BOOST)
16" wheels (already got these) and some form for lowering (coilovers probably)
Complete respray (suggestions on colour?? I am thinking pure white or a BMW sparkling colour)
Mk2 conversion (exterior - front end, bumpers, side skirts?) (Interior - Dashboard)
Will also add some luxuries like electric windows, EPAS, digi dash and an alarm
dgbnova#1
22-01-14, 10:45 PM
Well that is a bit of a change from the Carlton and it will be show stoping if you get on with it lol
I think rage has a td spare if u look at his van for sale don't know details though
Johnny A
22-01-14, 10:58 PM
Well that is a bit of a change from the Carlton and it will be show stoping if you get on with it lol
I think rage has a td spare if u look at his van for sale don't know details though
Rage's spare engine has a bent valve and also too far from me really
scott.parker
22-01-14, 11:02 PM
What the **** did i just read!?
lee 16v
22-01-14, 11:13 PM
That needs hatch back 3 door arches on it just to confuse people even more.
Johnny A
23-01-14, 09:13 PM
That needs hatch back 3 door arches on it just to confuse people even more.
It was done in euro land, it looked horrific!!
I have been keep my eye out for a 1.5TD lump on egay, gumtree and autotrader using a Corsa-B as a donor. Surprisingly there isn't many about, but there is buckets of Cav 1.7TDs for a few hundred quid. So I might be going for one of them.
dgbnova#1
23-01-14, 09:46 PM
You think hatch quarters on a saloon look horrific I cannot go with that at all they look far better and having done this myself it looks far better but I do like the estate as it is
I've never liked the round arches personally but each to his own
Johnny A
23-01-14, 09:51 PM
I think round arches only work on the saloon but a decent suspension drop is a must.
Round arches are much better. Nice drop and it will still be nice to drive. I wouldn't paint it white!
Johnny A
24-01-14, 07:30 PM
Round arches are much better. Nice drop and it will still be nice to drive. I wouldn't paint it white!
yeah but I wouldn't paint a car Arden blue ;)
Hahaha no Novas where in that colour back them....
Johnny A
24-01-14, 11:05 PM
VXR fanboy
Johnny A
25-01-14, 11:05 PM
I really want to get the engine started so I decided to work in the rest of the fuel system starting with the tank itself.
I bought this tank off someone on here about 5 months ago and hadn't even opened the box it came in! Listed as a second hand GTE tank I was expected much surface rust. In reality the tank is brand new!!!!
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn1/t1/1530468_10153693896355214_528444233_n.jpg
Not a factory one though?
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn2/1533898_10153693896600214_196805688_n.jpg
Painted:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn1/t1/67832_10153693896820214_2007103005_n.jpg
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-frc3/t1/1743740_10153693896940214_109331368_n.jpg
I was all happy about getting a new tank but the supplied fuel sender is a twist fit:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-frc1/t1/1013305_10153693897410214_793461014_n.jpg
Whereas the tank is designed for a bolt fit:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-ash3/t1/1009973_10153693897150214_56202627_n.jpg
Also I take it the larger pipe is the feed and the smaller pipe is the return????
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn1/t1/1538807_10153693897075214_183237860_n.jpg
dgbnova#1
25-01-14, 11:11 PM
You got a mounty tank lol
if your running gte pump you need the gte Gsi sender as it's feed from a 12mm pipe that's part of the sender
dgbnova#1
25-01-14, 11:12 PM
There defo a swirl pot in there ? And the other pipes are breathers
dgbnova#1
25-01-14, 11:14 PM
Edit it looks like a carb tank to me
Johnny A
25-01-14, 11:23 PM
There defo a swirl pot in there ? And the other pipes are breathers
There is definitely a swirl pot inside it mate, I did a visual confirm.
In the picture why is there two pipes on the back of the tank?? I know there is a second set of pipes on the upper section as breathers.
dgbnova#1
25-01-14, 11:26 PM
I don't know does the large on Feed from the pot and 12 mm if so it's the Feed to pump but the return is normally at the bottom front very odd
Johnny A
25-01-14, 11:34 PM
IIRC when I looked inside the big one did indeed go into the pot inside the tank, but IIRC don't both feed and return go back into the pot?
dgbnova#1
25-01-14, 11:42 PM
Yes they do must just be the way that one is made
never seen one like that
original ones return from the front over the top into the pot
the pickup is from the filter on the end of a pipe that's part of the sender unit that you are going to need anyway to bolt in unless the later tanks were all bolt in and a carb sender will do this I don't know I only mess with injection and early carb twist tanks
Johnny A
25-01-14, 11:59 PM
I will see if I can shove my phone into the tank with it set to record and use it like a probe to see where both pipes lead and then make a decision lol
dgbnova#1
26-01-14, 12:18 AM
Get a bit of wire from the outside poke it in and see we're it comes out
Tank looks completely normal to me. Larger pipe is feed smaller return. I fail to see the issue?
dgbnova#1
26-01-14, 10:47 AM
http://i1328.photobucket.com/albums/w535/dgbnova1/835DBB86-B641-4008-A94E-7EE409D89851_zps5nuzvzoj.jpg (http://s1328.photobucket.com/user/dgbnova1/media/835DBB86-B641-4008-A94E-7EE409D89851_zps5nuzvzoj.jpg.html)
Fuel on normal or gm tanks come via this pipe is all I'm saying plus return is on the front and asking why it looks like a carb setup as I'm sure if it's not working when fitted it's a bit of a pain in the ass
Ive confused myself now but it would seem I have one of these senders
Johnny A
26-01-14, 11:38 AM
Universal tank? They make one tank that is compatible with carb amd injection? You simply block the pipe you don't need?
dgbnova#1
26-01-14, 12:18 PM
Now that makes more sense no problem using a swirl pot on a carb if it's fed low there we go
Feed from the sender. Larger of the two front is return and smaller is a breather. Just spent hours searching iains thread and thats what I can make out from his
http://www.pngclub.com/forum/showthread.php?114446-Iain-s-20XE-Trackday-Nova/page145
His is an spi tank I know so his feed comes from the pump rather than sender
Johnny A
26-01-14, 08:52 PM
Feed from the sender. Larger of the two front is return and smaller is a breather. Just spent hours searching iains thread and thats what I can make out from his
http://www.pngclub.com/forum/showthread.php?114446-Iain-s-20XE-Trackday-Nova/page145
His is an spi tank I know so his feed comes from the pump rather than sender
Good work batman!
Today I started prepping the rear part of the floor and rear arches which consisted of a drill powered wire wheel and a tin of white Rustoleum. The floorpan was pretty much totally rust free with only a few bits of surface rust which were easily dealt with, Rustoleum is a rust killer as well as one coat paint - similar to Hammerite but it actually works in stopping rust. The rear arches are not the best if I am honest, the O/S arch has been rolled badly and the N/S has had a repair done at the end of the sill/start of the arch that was done by Stevie Wonder being helped by Mickey Mouse - basically welds that haven't fused and lots of filler to hide it all. It will need replacing :(
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn1/1653643_10153696621585214_78469586_n.jpg
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash3/1017663_10153696621680214_1637617107_n.jpg
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn1/t1/994129_10153696622245214_1054369004_n.jpg
The downside to Rustoleum is it takes ages to dry, in fact it will take all week to fully dry in this weather whereas Hammerite would be dry in a day. Anyway when I return on Saturday I will repair the bodged arch and seal the whole lot with Waxoil.
Before I left I decided to have a cheeky look at the Corsa-C 1.8SRi disc conversion, the assembly does indeed bolt straight onto a Nova beam!! The downside being an increase in track width by around 8mm per side, I am hoping with the rolled arches the wheels will clear.
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn1/62341_10153696621045214_2093738780_n.jpg
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn1/12344_10153696621240214_613466230_n.jpg
Rustoleum looks top job only ever saw it in spray can tho over here had thaught of hammerite for mine or por15 but have used Rustoleum on jeep wheels that are in and out of sea water with boat and rhere lasting fine
Johnny A
26-01-14, 09:57 PM
Rustoleum looks top job only ever saw it in spray can tho over here had thaught of hammerite for mine or por15 but have used Rustoleum on jeep wheels that are in and out of sea water with boat and rhere lasting fine
Ebay is your friend Damoh, it's not cheap though! Just purchased another 2.5L tin and it's cost me £40!!!!
8valve-craig
26-01-14, 10:11 PM
Before I left I decided to have a cheeky look at the Corsa-C 1.8SRi disc conversion, the assembly does indeed bolt straight onto a Nova beam!! The downside being an increase in track width by around 8mm per side, I am hoping with the rolled arches the wheels will clear.
Rolled arches and a sensible tyre works with them, I only flared mine at the back of the arch a little for better choice of track tyres.
The back of the stub axle and the mounting face of the disc could also be skimmed a little if need be.
Johnny A
26-01-14, 10:21 PM
Rolled arches and a sensible tyre works with them, I only flared mine at the back of the arch a little for better choice of track tyres.
The back of the stub axle and the mounting face of the disc could also be skimmed a little if need be.
TBH Craig I don't think I will need it, I have seen Allesios on Novas without rolled arches so I think I will be ok.
I was gonna say that same, take a 1 or 2mm off the disc face will help a bit.
Undersides look good.
Johnny A
02-02-14, 01:19 PM
Update: First up being a little concerned about the Corsa-C rear disc setup will push the rear wheels out too far so I decided to check.
https://scontent-b-cdg.xx.fbcdn.net/hphotos-ash3/t1/1604966_10153719191065214_2140921317_n.jpg
It's VERY close but it does clear:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn2/t1/1505420_10153719190990214_791681344_n.jpg
Before anyone says - this is the arch I mentioned before that was rolled by Stevie Wonder :(
It was cheaper to buy powerflex poly ARB bushes than genuine VX ones - go fig:
https://scontent-b-cdg.xx.fbcdn.net/hphotos-prn1/t1/1654422_10153719191270214_719713134_n.jpg
Undersealing it so much easier and quicker with a Schultz gun!
https://scontent-a-cdg.xx.fbcdn.net/hphotos-ash3/t1/1601192_10153719191440214_2139616264_n.jpg
I then got to work repairing the bodged N/S/R arch/end of sill, I should have expected this:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash3/t1/1150168_10153719191745214_1004912966_n.jpg
I had to cut out a section of the middle sill panel too, here is what is left being treated with rust killer:
https://scontent-b-cdg.xx.fbcdn.net/hphotos-ash3/t1/1779055_10153719191870214_1711538899_n.jpg
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash3/t1/1796496_10153719192090214_467363770_n.jpg
The middle panel was replaced and the outer skin welded in:
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-frc3/t1/1510750_10153719192420214_686723407_n.jpg
Considering how there is bugger all metal protection from the factory inside the sills it's a wonder this was the only rot after 21 years! This time I found some hammerite and covered everything inside the sills. Normally I would use Rustoleum but I needed paint that would dry in hours not days:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/t1/1013273_10153719192615214_2087259400_n.jpg
8valve-craig
02-02-14, 01:58 PM
In Picture 3 is that a new 1.8 handbrake cable in the bag? If so what parts did you buy?
Johnny A
02-02-14, 09:18 PM
In Picture 3 is that a new 1.8 handbrake cable in the bag? If so what parts did you buy?
the left and right one lol
8valve-craig
02-02-14, 09:26 PM
Wouldn't have guessed. Do they come with the metal holder? If so what brand are they?
Johnny A
02-02-14, 09:32 PM
Hell no, it's just the cables. I am adapting the Nova centre balancing holder to suit, the Corsa one is like £25!
maddogdaz666
08-02-14, 11:53 PM
Any progress Johnny boy?
Johnny A
09-02-14, 12:06 AM
yeah loads but I have been too lazy to take pics lol
Southie
09-02-14, 12:08 AM
Johnny, here's a photoshop I did for Burgo of his estate about 4 years ago... It's right up your street lol
http://i345.photobucket.com/albums/p379/SOUTHIE01/shoppery/PNGBURGO-TANKTrax.jpg (http://s345.photobucket.com/user/SOUTHIE01/media/shoppery/PNGBURGO-TANKTrax.jpg.html)
Johnny A
23-02-14, 02:44 PM
Update:
Sorry for the lack of updates over the past few weeks, unfortunately life took over and I could only do small amounts of work - most of this was wiring so no real point in updating. Today another setback with me being ill, suspected kebab retaliation from last night :roll:
Wiring:
Most of the additional systems are now in place, off the top of my head the only wiring left to do:
Heated front seat harness - Not started
Footwell illumination - Not started
Boot lighting - Need to source and wire up trigger switch
Fuel pump - Female spade connectors need popping onto wires
Speedo drive - ABS pickup needs wiring, 12v amplifier and pulse converted need installing
Alarm/immobiliser - Need to install and wire up power sounder
Along with installing central locking I wanted to drive it directly off the alarm (not using any GM hardware or wiring), I bought 3x strong solenoids and popped one in each door. The third was for the boot (pretty sure some top end Novas had central locking on the boot), however looking at the boot release button and mechanism there was no facility to lock/unlock the locking barrel. Instead I came up with the idea of connecting the third solenoid to the latch release rod and (via a relay) use the alarm's axillary control channel to activate it, only real problem was the angle the rod needed moving without any room to fit the solenoid to pull in the same direction.
To get around the problem I welded bicycle cable clamps onto the latch rod and solenoid rod, adding a bike cable and pulley to allow the solenoid to be placed out of the way:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/t1/1653283_10153792408330214_1690897350_n.jpg
It works a treat, these solenoids are rated at 5kgs pulling force so are more than ample. Bare in mind the boot is a rare non-wiper (read: super poverty spec) but with a normal gas strut, this means the boot opens without any assistance - hit the button on the alarm fob and the boot opens on it's own!
To try and keep the interior clean and professional I decided to integrate the alarm's ultra sonic sensors into the mirror bracket:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-frc1/t1/1013320_10153792408280214_504687397_n.jpg
Here is the amplifier in the wheel well:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn1/t1/1618616_10153792408400214_1167015481_n.jpg
Now due to the thickness lost in the wheel well I still wanted a spare well just in case - a space saver is the only real option here. A few obstacles to overcome were finding one thin enough to hover over the top of the amplifier without protruding into the boot and a spare wheel large enough to fit over the Cally turbo front brakes. I found a 16" 4-stud space saver from an Astra-H, the rim thickness itself was ideal but the centre stuck out:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn2/t1/1782129_10153792471795214_427579479_n.jpg
I took a grinder to it, cutting the welds that join the rim to the inner part and hammer it out. I cleaned it all up, flipped the middle and pressed it back in backwards - this had the effect of making the whole wheel no wider than the rim itself:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/t1/1619476_10153792408810214_415954530_n.jpg
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-frc1/t1/1959473_10153792408590214_1999383333_n.jpg
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn2/t1/1797480_10153792408640214_1676791765_n.jpg
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-frc1/t1/1958398_10153792408885214_2046347596_n.jpg
All I need to do is make a bracket to hold the wheel now.
My plan for today was to continue working but due to the killer kebab I couldn't take pictures of the work I have done on the Corsa-C disc rear beam conversion. I do actually wonder if anyone has done this conversion because it was more work than expected.
First off it's true to the assemblies bolt straight up to the Nova beam, but the cable mechanism needs a fair few modifications. I bought both left and right cables (Corsa-C) from Vauxhall, they are routed the same way as the Nova which is handy.. in fact the Nova balance bar is 100% compatible too!! But that's the last of the easy bits, I welded the cable guides onto the Nova beam making sure the cables didn't foul the shocker or the spring. Originally I planned to run gaz rear coilovers but by the looks of things the cables would rub on the springs, so normal shocks and springs will be used (probably better for ride comfort anyway). The primary cable is too long by about 4-5 inches so a spacer bracket is needed.
The last issue is adjustment, the standard Nova drum setup uses an adjuster on the end of the short cable at the balance bar but on the Corsa setup the adjustment is done at the handbrake handle to primary cable bracket. I was half way through the process of converting the Nova handbrake handle to run an adjuster but I stopped when I ran out of time. Pictures will have to wait till next week.
Looking good john, love the rim.
Johnny A
20-03-14, 08:36 PM
Update:
New securing mounts for the fuel pump:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn2/t1.0-9/1393744_10153879084520214_415967798_n.jpg
Painted fuel pump cradle with new rubbers and stainless bits:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-frc3/t1.0-9/10150553_10153879083960214_2118125752_n.jpg
Fitted:
https://scontent-b-ord.xx.fbcdn.net/hphotos-prn1/t1.0-9/1920167_10153879083770214_2070458269_n.jpg
Cable shifter in place:
https://scontent-b-ord.xx.fbcdn.net/hphotos-frc3/t1.0-9/1458427_10153879084780214_1287967494_n.jpg
Nice curve on the cables, shifter is still a bit stiff as the cables are old and nasty - but for now it's fine:
https://scontent-a-ord.xx.fbcdn.net/hphotos-frc3/t1.0-9/1978702_10153879084490214_153920793_n.jpg
Shot of the pedalbox area, you can see the heater box on the left, EPAS steering column right and hydraulic clutch assembly middle:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-frc3/t1.0-9/1972418_10153879084770214_276387154_n.jpg
https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/t1.0-9/1972365_10153879084695214_1936077132_n.jpg
https://scontent-a-ord.xx.fbcdn.net/hphotos-ash3/t1.0-9/1524691_10153879085320214_1365296013_n.jpg
Carpet going in:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-frc3/t1.0-9/1926881_10153879084960214_559051599_n.jpg
The (very dirty) calibra drivers seat trail fitment, it's surprising how little mods are required to make it compatible with the Nova subframes :D
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/t1.0-9/1904160_10153879085160214_1700082419_n.jpg
Space saver wheel with it's tyre on, fits like a glove:
https://scontent-a-ord.xx.fbcdn.net/hphotos-prn1/t1.0-9/1011042_10153879085315214_789658652_n.jpg
scott.parker
21-03-14, 10:19 AM
Interesting idea with wheel, its how some people make deep dish steels from two diffret wheels.
And correct me if I'm wrong, but i thought this car was for your mum. lol
johns mum has all the best cars!
gary_126
21-03-14, 09:25 PM
looking forward to seeing this finished, so many unique mods.
Johnny A
21-03-14, 09:39 PM
Yep this is still going to be mums car! Jealousy will get you no where lol
scott.parker
21-03-14, 09:42 PM
Not jealous dude, just wondering if she'll want to drive it once it's finished lol it would be a mental car to give to my mum...
jimbob-mcgrew
31-03-14, 02:37 AM
just read it all, great projects man.
a lot of decent work gone into your cars. :thumb:
a mate of mine used to own that 'burgo' estate... altho it was a saloon back then, and blue.
whats happening with the rwd one by the way ?
Johnny A
31-03-14, 07:50 PM
just read it all, great projects man.
a lot of decent work gone into your cars. :thumb:
a mate of mine used to own that 'burgo' estate... altho it was a saloon back then, and blue.
whats happening with the rwd one by the way ?
Thanks man, a lot of the blue still remains on the inside lol
The RWD one is in the list for work, it will the last project due to it's complexity
Johnny A
06-04-14, 08:27 PM
Small bit **** update:
Fuel tank tar strip thingys added, just used sound deadening:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-frc3/t1.0-9/970730_10153936357315214_2460156447079762964_n.jpg
I used some spare 22mm silicone hose for the breather conduit pipe that goes through the chassis rail:
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash3/t1.0-9/1948054_10153936357800214_1667578549058870304_n.jp g
Like so:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn2/t1.0-9/1506958_10153936357580214_6112664637451870937_n.jp g
Tank all bolted up:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/t1.0-9/1902796_10153936357505214_7980274739654871628_n.jp g
Covered in grubby paw prints though:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-frc1/t1.0-9/1947916_10153936357675214_8104080183780647729_n.jp g
Filler neck attacked with a wire brush:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-ash3/t1.0-9/10170703_10153936358065214_4802140392943496224_n.j pg
Painted:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash3/t1.0-9/1904165_10153936358195214_938219280373712859_n.jpg
Instead of buying a rip off Vauxhall genuine fuel tank filler rubber pipe I bought 1 meter of flourine lined silicone hose:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn2/t1.0-9/1901917_10153936358160214_1562482076569495616_n.jp g
I can't find a blue carpet set so instead blue mats:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash4/t1.0-9/10151863_10153936358085214_8509755893027895198_n.j pg
Johnny A
15-04-14, 10:39 PM
Small update:
The Corsa-C rear disc handbrake cables needed custom brackets to work:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-frc3/t1.0-9/10247266_10153968416835214_6317083900220922656_n.j pg
The primary cable comes in from the left, the bracket in the middle is a combo of a standard nova one and a nova balance bracket. The handbrake handle's bar had a threaded rod welded on and the balance bar's adjuster is used to tension the cables.
Fuel filler neck bolted in place:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/t1.0-9/q82/s720x720/10169304_10153968416620214_4018210657119047502_n.j pg
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn1/t1.0-9/p180x540/10150677_10153968416925214_6094527529546979847_n.j pg
Attached to tank with silicone hose, also a new fuel filter and fuel lines:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn1/t1.0-9/q74/s720x720/923207_10153968416535214_613653222782420063_n.jpg
Johnny A
05-05-14, 11:08 PM
Update:
As some of you know my Carlton/touring car/wtf/estate thing caught fire at Combe and it was later found out the underlying fault was no.2 piston ring died - still though means more time for the Nova!!!
The rear beam with Corsa-C stuff:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/t1.0-9/10177904_10154038709620214_3706153104886160121_n.j pg
Does anyone know if this conversion has been done before now? Because aside from the hubs bolting straight up to the beam it's not as easy as I expected.
The trimmed down original Nova balance bar (notice the Corsa-C stuff doesn't utilise an adjuster here):
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn2/t1.0-9/10338738_10154038709525214_4549853454357482402_n.j pg
Thanks to Craig for the GTE front tie bars and ARB, replacing the thinner stuff:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-frc1/t1.0-9/10262132_10154038709850214_4496857036805869133_n.j pg
https://scontent-b-lhr.xx.fbcdn.net/hphotos-ash3/t1.0-9/10246351_10154038710240214_1723229457578707814_n.j pg
Brackets and bushes, funnily enough the powerflex poly bushes are cheaper than buying GM gear:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn2/t1.0-9/10277030_10154038710065214_402293170360001432_n.jp g
The factory 20XE downpipe has about an inch of secondary pipe removed to bring it tighter to the sump for extra ground clearance:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-frc3/t1.0-9/1966852_10154038710540214_4818703855219013827_n.jp g
I refitted the rear beam minus the rear brake assemblies as they are being painted, here you can see the pump assembly with fuel lines:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-frc3/t1.0-9/10171053_10154038710835214_5538823127447257498_n.j pg
As I running a single rear brake flexi onto the beam it frees up the O/S pipe holder to make a very handy fuel line securing point:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/t1.0-9/10329147_10154038711065214_6589290295684335594_n.j pg
With a new GM fuel tank 'S' pipe return fitted to the tank this completed the fuel system and I moved back onto the rear brakes now the paint was dry:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash3/t1.0-9/10262236_10154038711390214_6592478997974485089_n.j pg
Ohh that's looking nice, extra points for colour coded the handbrake mechanism on the rear of the calipers:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-frc3/t1.0-9/10157157_10154038711765214_8574523971129017788_n.j pg
I don't know if anyone has noticed but originally I bought rear Gaz coilovers for this build, if so you may wonder why they are not being used, this is the reason why:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-ash4/t1.0-9/10334373_10154038711500214_1835736945246157124_n.j pg
The handbrake cables run within 2mm of the shocker body - not enough room :(
Not to worry they can go on the estate instead :thumb:
Handbrake balance bracket in place with silicone hose rings replacing the original rubber bumpers:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-ash3/t1.0-9/10177888_10154038711675214_8021491198385196854_n.j pg
The front handbrake bracket got the same treatment and the adjustable is all copper greased up:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn2/t1.0-9/10269574_10154038711895214_6838864651389615991_n.j pg
I have done a lot more than this but as it's simply wiring there are no pics, but off the top of my head:
Corrected an alarm fault which caused the alarm to deactivate all the immobilisers with the ignition was on (as it should) but then re-activate them the second you tried to start the engine)
Completed the rear chassis loom and connected it to the boot harness
Tested the alarm system, door locks and remote boot opening (very trick)
Tested the electric power steering - works fine but adjust ability doesn't work on the dial... seems to be either off or 100% assistance - even with the 300mm small steering wheel, 2.5 turn rack and 195 tyres digging into the floor (stationary) it still makes the turning super light!
Wired up the fuel pump, horn, cooling fan
Installed blue seat belts and full length rear 1/4 cards
maddogdaz666
06-05-14, 08:52 AM
Nearly there now then!
but after painting so many parts I thought the axle would have got a lick of paint too?
Looking good john, did you mock it to see if the cable would run under the coilover plate form?
Johnny A
06-05-14, 08:56 PM
Nearly there now then!
but after painting so many parts I thought the axle would have got a lick of paint too?
Time is a factor here mate so I decided to leave it for now, but yes I agree it sticks out a bit!
Johnny A
06-05-14, 09:07 PM
Looking good john, did you mock it to see if the cable would run under the coilover plate form?
Cheers Ben, I didn't mock it however the handbrake lever can be modded to have the cable underneath. However I suspect that doing so would cause more issues with the cable routing.
Johnny A
14-05-14, 08:50 PM
Update:
I am very pleased to say that someone has bought the Carlton estate chassis and suspension setup so she will live again!!
Sorry Nova stuff right!?
Well we are very very close people!! SEF gets MOT'd on Friday and I am putting him together very quickly!
I bled the brake system and hydraulic clutch... both bled perfectly first time. The fully untested clutch works very well - nice and smooth :D
I needed to fill up the caliper pistons on the back so they aligned.... but they wouldn't fill up! After a few seconds I realised the bias valve was set mostly to the front, dialing it to 50/50 got them to fill up fine. After that the handbrake was tested and it works really well too :D
Engine bay ready:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/t1.0-9/10314520_10154071608330214_3375515064172799891_n.j pg
Temporary front end in place:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-ash3/t1.0-9/1966937_10154071608830214_3141084218162440416_n.jp g
Nice little addition, these are wired into the boot switch:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/t1.0-9/1901436_10154071607470214_720033099914185614_n.jpg
The light coming from outside the unit is direct sunlight.... this should give you an idea of how bright the lights are:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-frc3/t1.0-9/10336648_10154071607790214_5224814697628593865_n.j pg
Astra twin squirter jets:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-frc3/t1.0-9/10376016_10154071608485214_7604599923905663308_n.j pg
How about this for a man toy?
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn2/t1.0-9/1377121_10154071607590214_5521239312609798800_n.jp g
It's very small and jump started the car no problems!!
Things to come:
Well I am off work till next Friday so expect lots of updates!
SEF custom exhaust system on Friday followed by MOT
More work on SEF Saturday
Astra 1.7TD has it's engine removed Sunday morning followed by the delivery of my Nova Estate!!!
Work to follow next week on the estate to prepare it for the road.
dgbnova#1
14-05-14, 09:31 PM
So that's what the extra boot lights were for you do have some great ideas Johnny love it and still miffed you got the estate lol
Love the boot lights, very tidy.
Very worrying update Johnny, I'm in the process of fitting my Corsa C rear disc setup and haven't envisaged clearance issues there. Also running Gaz rear coilovers that are away for refurb so can't even mock it up argh
I know 8v Craig moved his shock bodies in to suit turrets so won't have had those issues on his.
dgbnova#1
15-05-14, 02:39 PM
I've not looked at these breaks tbh but I've had problems before I just made up what I needed from a stock item then took that as a template to a cable place not far from me and they made it to suit simples
My cables rub on the spring and i've had to notch the chassis.
Johnny A
18-05-14, 10:34 PM
Update: MOT - PASS!!!
Friday morning saw SEF go in for his exhaust system - a stainless twin box 2.25" system with a 2.5" outward rolled tip:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn1/t1.0-9/1554515_10154085925170214_4357165838260989365_n.jp g
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn2/t1.0-9/10269570_10154085924825214_5550903094049778637_n.j pg
I am really happy with how clean and new the underside is:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-frc3/t1.0-9/10401398_10154085925005214_4090303385605841201_n.j pg
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn2/t1.0-9/10338309_10154085925555214_2083019558006419347_n.j pg
The finished product - very chuffed and sounds good without being loud:
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-prn2/t1.0-9/10372216_10154085926570214_4475660699712191380_n.j pg
That evening I managed to sneak in a shot of the boot lights at dusk:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-frc3/t1.0-9/10170826_10154085926675214_4388967513148000197_n.j pg
Saturday saw the MOT and Tax with no dramas, I also got the tracking done. Unfortunately the EPAS stopped working, it turns out the cheap ebay special controller is to blame.
2.8 Turn steering rack + XE boat anchor + 300mm steering wheel + big fat tyres + tight parking isn't fun
Sunday saw me strip the Astra3 1.7TD for it's donor engine, Burgo and his brother delivered the Nova Estate and took the Astra:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn2/t1.0-9/10373671_10154085969570214_1098283965173095130_n.j pg
Now in my possession!!
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn2/t1.0-9/10300908_10154085969345214_7692716706192732749_n.j pg
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn2/t1.0-9/10157129_10154085970120214_2080731581172875289_n.j pg
dgbnova#1
18-05-14, 10:42 PM
It looks at home with that boat
the white one looks spot on now love the exhaust
Exhaust looks great, where was it done in the end?
Estate needs some loving now dont it... luckily you're just the person to do it.
Estate needs some loving now dont it... luckily you're just the person to do it.
Agree! I seen the thread where it was made, but nice to see it's in good hands now! An Estate rebuild project thread also whould be cool :)
Johnny A
19-05-14, 06:20 PM
Cheers for the comments guys, today I did 320 miles to collect a ton of GSi parts for both Novas. No dramas from the car, it drove perfectly.
L33 LEG
19-05-14, 06:30 PM
Good to meet you today mate. Very impressed with the car doing so many miles on its first journey.
Aome very decent parts and touches on the nova. Will be a stunner once it's finished.
Johnny A
22-05-14, 09:31 PM
Good to meet you today mate. Very impressed with the car doing so many miles on its first journey.
Aome very decent parts and touches on the nova. Will be a stunner once it's finished.
Cheers, I got home with no dramas either.
Update:
Since the first road trip I have been refining the design, certain systems were still either not working as they should or not at all.
The EPAS: During testing this working fine, however before I could drive the car it stopped working. I suspected the cheap ebay controller and I was correct, I pulled it apart and the circuit board was a hashed together mess and so was immediately binned. The EPAS ECU requires two signals to operate, one is engine speed (revs) and the other is vehicle speed. Revs is easy as the engine ECU outputs a rev signal for the digi dash, the vehicle speed is a little more tricky - it required a second pulse converter running in parallel with the first one driving the speedo. It started working once wired up with the added bonus of it being speed-sensitive now with the facility to adjust the amount of sensitivity based on speed :D
After a drive I was very impressed by it, it's super light at low speeds and gets heavier as the speed does up! Trouble is the steering was lighter turning left than right so the torque sensor needed resetting.... so out comes the dash again!! The sensor adjustment is easy but along with the dash coming out the column needs to be disconnected from the rack so it's a lot of messing about for a 5 minute reset.
With the dash out I decided to tidy up the wiring a bit and fit the dash speakers, these speakers have huge magnets - there was no way the dash could support them. So I came up with speaker mounts that are welded onto the chassis itself:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-frc3/t1.0-9/1907992_10154099813450214_7322572219470872627_n.jp g
https://scontent-b-lhr.xx.fbcdn.net/hphotos-prn1/t1.0-9/10376293_10154099813095214_1358995286914632063_n.j pg
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn2/t1.0-9/10379021_10154099813295214_5415090302532454425_n.j pg
These speakers are part of a 3 way component set with tweeters and 8" woofers for the doors
With the dash back in and the steering super light both ways I turned my attention to the throttle, on the long first drive I found the pedal was very heavy... so much so that the amount of pressure required causes my foot to go numb :(
The cable routing seen here was to blame:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-frc3/t1.0-9/1476446_10153576520745214_1930652165_n.jpg
Using a fancy bracket and a pushbike cable pulley I came up with this:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-ash3/t1.0-9/10405278_10154099812150214_7804322228678639160_n.j pg
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-frc3/t1.0-9/10300272_10154099811930214_5946291701790496503_n.j pg
This helped a lot, but I went a stage further a relaxed the main throttle body spring so the throttle and nice and light now :D
Next up was to fit the front anti roll bar, even with the raised engine it still fouls the exhaust downpipe. Instead of some bodge-tastic ARB lowering block I made some more work for myself and lowered the front tie bar brackets by 35mm:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn2/t1.0-9/1797466_10154099812445214_4331599113975644147_n.jp g
Lastly I found a slight kink in the fuel feed line from the tank:
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn2/t1.0-9/10341696_10154099812750214_2039043592832574330_n.j pg
A bit of 90 degree fuel safe silicone fixed it though:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn1/t1.0-9/10346511_10154099812810214_7780328448718867255_n.j pg
Johnny A
01-06-14, 09:29 PM
A little work done on SEF this saturday:
Aside from some suspension tweaks and subsequent tracking alignment again mumsie wasn't happy with the throttle pedal, she said it was too hard and also didn't like how high it was.
30 mins with a grinder and the welder fixed that:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xfp1/t1.0-9/10367155_10154133224515214_5774707106475729045_n.j pg
the bar is extended by an inch to bring the pedal down to the same level as the others:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10325341_10154133224165214_3702051044071158815_n.j pg
The results were amazing, the extra leverage makes the pedal as light as a brand new modern car and the new position does make it more comfortable to drive. This mod will definitely be carried out on the estate in due course!
Sunday saw me start work on the estate, I started off with this:
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xaf1/t1.0-9/10296767_10154137105670214_8307650559485675480_n.j pg
Stripped down:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xap1/t1.0-9/10433934_10154137105785214_7783750728471568961_n.j pg
Cheeky:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-xap1/t1.0-9/10402394_10154137105925214_3073585059201078961_n.j pg
The two gearbox mounts gave the alignment I needed and a trolley jack was supporting the engine underneath:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10313496_10154137106425214_6937907979503550997_n.j pg
Here is what I am presented with, you can see the factory petrol Nova engine mount bracket on the chassis rail and also the bracket on the engine itself..... not exactly an easy job to fix:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xap1/t1.0-9/10257376_10154137106705214_1865593470043870025_n.j pg
Although I had considered making some sort of bracket similar to petrol models and using the petrol bracket on the chassis I decided against it. As you can see there isn't much room for a bracket on the block and there is also the issue of the alternator being in the same area:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-xap1/t1.0-9/10442354_10154137107065214_7944463597980108480_n.j pg
This is actually something me and Burgo had talked about as I was worried about the mount on the block snapping (common problem on the 1.5TD Novas), so we both agreed with the best method was to adapt the much stronger Astra mounting onto the Nova:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xfp1/t1.0-9/10435912_10154137107470214_1055857220694959021_n.j pg
Mark up:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xap1/t1.0-9/10365895_10154137107310214_4107068322580029024_n.j pg
Attack with grinder:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-xpa1/t1.0-9/10360846_10154137107685214_2484171963811831901_n.j pg
Put engine back in a check:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpa1/t1.0-9/10398670_10154137108035214_8323762987731941_n.jpg
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10380924_10154137108390214_317074121639273173_n.jp g
I also checked to make sure the mount wouldn't foul the Nova TD header tank or pipes:
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xap1/t1.0-9/10360846_10154137108480214_7360180553673570310_n.j pg
This is how I left it, on Saturday I will weld the astra bracket in place and then brace the crap out of the chassis rail!
https://scontent-b-lhr.xx.fbcdn.net/hphotos-xap1/t1.0-9/1506988_10154137108595214_9046075319626407628_n.jp g
dgbnova#1
01-06-14, 09:56 PM
Not hanging about then john you not thought about running 2 mounts in that side as looks like can pick up off the block
Johnny A
01-06-14, 10:06 PM
Not hanging about then john you not thought about running 2 mounts in that side as looks like can pick up off the block
Unnecessary mate, the Nova 2-bolt engine brackets are the ones that fail. The much larger 3 bolt astra/cav/vectra mount can take the punishment.
Johnny A
03-06-14, 10:06 PM
Everybody loves car porn:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xap1/t1.0-9/10429371_10154143146630214_6527429032761781096_n.j pg
Ooooo that it very nice. Every way adjustable.
maddogdaz666
04-06-14, 08:40 AM
:wisewood: :wisewood: :wisewood: :wisewood: :wisewood: :wisewood:
dgbnova#1
04-06-14, 11:12 AM
That's a nice bit of kit
Johnny A
06-06-14, 11:42 PM
Wiring fun!!
My copy of TIS2000 doesn't cover the Astra-F so I needed to open up the engine wiring harness and map out all the wires, the reason being:
I want to cut and shut the harness to suit the Nova engine bay for the OE look
Some of the systems were confusing
It took an hour to strip and map the harness and another hour to make a pretty picture on photoshop:
https://scontent-a-cdg.xx.fbcdn.net/hphotos-xaf1/t1.0-9/10411748_10154155722250214_5202350869748822228_n.j pg
As you can see the majority of it is part of the glow plug and fuel pre-heater circuits, I really want to retain the factory immobiliser circuit (immob pump) but I need to find out what wiring and hardware is needed at the other end for it to work. If I can't keep it all I need to do is smash off the decoder box on the back of the pump, find the solenoid wire and connect it directly to the black/yellow trace wire so it opens when the ignition comes on.
I also want to replace the Isuzu oil pressure switch on the block with a GM switch/oil pressure sender so the digidash gauge works correctly
Johnny A
10-06-14, 08:35 PM
Updatings!
The Astra engine mount bracket going in:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xap1/t1.0-9/10394588_10154169549410214_7691015140383974273_n.j pg
The inner arch has been hammered inwards so that when I have the big wheels on they won't rub on lock
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10383486_10154169549535214_3209084244880273132_n.j pg
https://scontent-a-cdg.xx.fbcdn.net/hphotos-xpa1/t1.0-9/1528564_10154169549675214_7482280264550553548_n.jp g
I got bored with the engine mount so decided to start work on the suspension turrets, I purchased some brand new Gaz ultra low coilovers so I saw no need to raise the turret tops themselves, with a little machining the 200SX shiny top mounts were bolted up to the coilovers:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xfp1/t1.0-9/10300966_10154169555540214_813868580824013476_n.jp g
I used to own a Toyota Aristo, which used the same top mounts as the 200SX. The Aristo had a factory strut brace with these spacers.... which was handy I had lying about:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xfp1/t1.0-9/10336851_10154169555385214_1431428595484794734_n.j pg
Used them as a template:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/10363118_10154169556450214_6091690160497388907_n.j pg
15 minutes of grinding, drilling and cutting saw this:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/10406951_10154169556000214_6466886030276731895_n.j pg
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xap1/t1.0-9/10441107_10154169556170214_4783830380248900912_n.j pg
Inside the turret:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xap1/t1.0-9/10373994_10154169556205214_7150955314355987484_n.j pg
Unlike the eccentric top mounts other nova owners have to use which seem a bit annoying and clumsy to adjust these require a loosening of the allen bolts:
https://scontent-b-cdg.xx.fbcdn.net/hphotos-xfp1/t1.0-9/10373971_10154169556315214_78534005471794504_n.jpg
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/1604737_10154169556485214_9145875311861469823_n.jp g
With the plate bolted over the top, I will weld this on at some point:
https://scontent-a-cdg.xx.fbcdn.net/hphotos-xpa1/t1.0-9/10385385_10154169556620214_8392444371504865109_n.j pg
https://scontent-a-cdg.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10464055_10154169556790214_6925129539571795635_n.j pg
Top view shows how much negative camber you can generate:
https://scontent-a-cdg.xx.fbcdn.net/hphotos-xpa1/t1.0-9/10350613_10154169556860214_1469899953329566689_n.j pg
Johnny A
10-06-14, 08:35 PM
With an hour left I added another few plates to the engine mount:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10361056_10154169556985214_7228116512870525173_n.j pg
As always I like to stay ahead of the curve, why use an Astra digi dash when you can use a Carlton one?
https://scontent-a-cdg.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10292141_10154169549740214_5883741585493472375_n.j pg
A nice haul from PVS thanks mostly to Dave (Dgbnova#1):
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xfp1/t1.0-9/10304971_10154169549830214_6817026471041348454_n.j pg
and finally a quick picture of the heavily modified front crossmember, this is it on the RWD Nova Saloon. This front end is as stiff as the factory item but it's very thin so air flows through 100% of the FMIC and also is mounted further back for a tidier look:
https://scontent-b-cdg.xx.fbcdn.net/hphotos-xpa1/t1.0-9/10380317_10154169557255214_4096157376041208811_n.j pg
Love the top mount and turret combo. Very very nice way of doing it. I love that.
Agreed top mount setup looks proper much better than a typical eccentric set up.
dgbnova#1
10-06-14, 11:00 PM
Well that's a result on the top mount looks spot on less work than you were thinking is that because of the shorter shocks ? Any they line up on the ridges of the strut top spot on great mod
Johnny A
10-06-14, 11:31 PM
cheers guys, I am very chuffed with the top mounts.
Here is the Carlton digi dash warmed up:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/10441206_10154170200780214_8645113185894266539_n.j pg
8valve-craig
11-06-14, 07:33 AM
So they only adjust camber then? No castor adjustment like the typical Nova top mounts?
Johnny A
11-06-14, 08:29 AM
Yes you can but I don't need to for this build
Johnny A
12-06-14, 09:28 PM
Today I continued working on the engine bay area, finished up the engine mount:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xfp1/t1.0-9/10397844_10154176336430214_4839598713809828266_n.j pg
Inside the arch too:
https://scontent-b-cdg.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10421286_10154176336345214_6953574936075111155_n.j pg
I needed to repair some rust I saw on the bulkhead by the battery tray area, I cut the top panel section out for access:
https://scontent-b-cdg.xx.fbcdn.net/hphotos-xap1/t1.0-9/1959328_10154176336555214_3990633817042386904_n.jp g
Once I started attacking the area with a wire brush on a grinder it was apparent there was a fair amount of tray rust - I found a backstreet garage MOT style welded in plate (over the top of the rust) and covered in seam sealer to hide the sins, I didn't have to grind the plate welds back - they were so bad I just prised it off with a screw driver. This is what I was left with:
https://scontent-a-cdg.xx.fbcdn.net/hphotos-xpf1/t1.0-9/1510971_10154176336815214_59232306466441086_n.jpg
https://scontent-a-cdg.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10404269_10154176336915214_561291470829314603_n.jp g
You can see the square area where the plate sat:
https://scontent-a-cdg.xx.fbcdn.net/hphotos-xfp1/t1.0-9/10402512_10154176337045214_937634776764291902_n.jp g
I am going to leave it for now, I have ordered a new battery tray and will sort it all out once it arrives.
I had the old tyres removed from my alloy wheels:
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-xfa1/t1.0-9/1908027_10154176418225214_7674078940439066660_n.jp g
These wheels were made by MIM and originally off a E11 Toyota Corolla TTE limited edition, some sort of rally inspired version.
Not only do they look awesome but are 6.5x16" ET45 4x100! The only downside is that the centre bore on the Toyotas is 54.1mm and the Nova is 56.6mm, so tomorrow the wheels go off to the machinist to open up the bores a bit.
dgbnova#1
12-06-14, 09:43 PM
Good progress mate and wheels look MIMt lol
Tidy welding John.
Love the new rims too.
Johnny A
13-06-14, 11:02 PM
Well the wheels are dropped off, I expect to get them back early next week at which point I will be simulating fitment and ride heights.... much excite!
Today I did one thing - fitment of the drivers seat. A right pig of a job! You guys know how hard I like to make things for myself, well the seat would not be in factory position.
Things to consider are:
Due to my lanky legs I wanted the seat further back than the rails allow, so the seat needs to be mounted further back but still allow for adjustment should a short ass drive it.
Due to my big ass head I wanted to sit lower
Try and use the factory bolting points on the floorpan
5 hours later and I got the seat where I wanted it, about 2.5 inches lower and 2 inches further back with the front mounting bar in position. I had to loose the rear brackets though and will fabricate some custom ones tomorrow.... along with some pics :)
Vlietje
14-06-14, 07:06 AM
Good progress Johnny!! Love the turret mod. Keep it up matey.
Danhart
14-06-14, 03:16 PM
Just read through, some great ideas and the 1700 dervs are an amazing starting place for big boost, I mean, that's what we go derv for!
I feel the mount is a good idea, but quite overkill, I've never had problems with the standard structure once I fabricated a suitable mount, would definitely advise you look for back up gearboxes though!
Johnny A
15-06-14, 12:37 PM
So the f18 won't be able to handle the power??
Danhart
15-06-14, 02:03 PM
So the f18 won't be able to handle the power??
Im im yet to give my verdict, but I've killed 2 so far, but both were high milage, problem I get is pulling from say 25mph in fifth, getting to peak torque/turbo coming on and I see to strip to gears teeth
them top mounts look awesome, fair play
dgbnova#1
15-06-14, 02:28 PM
Im im yet to give my verdict, but I've killed 2 so far, but both were high milage, problem I get is pulling from say 25mph in fifth, getting to peak torque/turbo coming on and I see to strip to gears teeth
That's easy to fix I'm sure you can fix that no problem , don't do it !
Ive seen 3 of these boxes fail on standard road cars but also high miles but I do think driving style played part to 2 of them
things break that's the reality
Johnny A
16-06-14, 01:07 AM
I will bear it in mind but I am pretty good at mechanical sympathy.
Update:
After 5 hours the drivers seat is sitting pretty:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/10456243_10154188578685214_4794738370620607315_n.j pg
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With the drivers door shut the leg bolster is about 1mm away from the door card pocket:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/10378938_10154188579085214_3375427137815574540_n.j pg
Modified rail section of the subframe:
https://scontent-a-cdg.xx.fbcdn.net/hphotos-xpa1/t1.0-9/10402910_10154188578810214_6311375683505999611_n.j pg
Positioning, first up is a picture of SEF's front seat as far back as it goes:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/10370375_10154188579300214_315776940150850548_n.jp g
and the estates seat as far back as it goes:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10297790_10154188579400214_6476358190352090045_n.j pg
The steering column alignment correction and replacement with corsa epas:
Using the seat and pedals as a reference you can see how pissed the column is from the factory - this is my pet hate on a Nova (apart from them being FWD lol):
https://scontent-b-cdg.xx.fbcdn.net/hphotos-xap1/t1.0-9/10457922_10154188579535214_6328135231549300116_n.j pg
The corsa-b epas column is shorter than the Nova version, this helps a lot for correcting the alignment:
https://scontent-a-cdg.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10305417_10154188579765214_2817023033381485579_n.j pg
The factory column's rear bracket is used as a basic reference as it's in-line with the brake pedal on the pedalbox - more on why later:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/10433295_10154188579885214_9195193187862621390_n.j pg
The factory column bracket is removed, cleaned up, trimmed and spot welded back on in it's new position:
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10364038_10154188580125214_531941966129989070_n.jp g
https://scontent-a-cdg.xx.fbcdn.net/hphotos-xap1/t1.0-9/10443494_10154188580230214_7111812987546851934_n.j pg
This is rough for now, the left-right location is perfect as I was able to use the seat to align it. However the tilt and distance from the bulkhead will need tweaking, things I am considering:
Epas motor interaction with bulkhead
Output shaft interaction with bulkhead, pedalbox and how this will effect the column linkage to the factory steering rack
New tilt angle - the original angle is around 30 degrees from horizontal which I don't like... want around 10 degrees
New distance from bulkhead - The threaded rod on the column bracket to bulkhead distance is 5.2 inches and looking at SEF there is at least 1 inch between the bracket and the dashboard - I plan to move the epas out to a total of 6 inches bulkhead to threaded rod. This brings the steering wheel a little closer to me (sorta needed with the seat so far back) and also provides some much needed room at the bulkhead end.
Column interaction with Mk2 dashboard
Johnny A
16-06-14, 04:49 PM
Not much going on today, I did get my alloys back from the machinist:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10382747_10154191357605214_8868641460087613524_n.j pg
A nice angle shot showing the super flat spokes and nice bit of dish on the centre:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10372012_10154191357525214_2219448373954835463_n.j pg
Also the replacement battery tray arrived, it's not the best steel pressing ever but it's thick enough and I am sure it will fit fine:
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/10421425_10154191357760214_8590105117916034446_n.j pg
Nice buy, where was that from?
Johnny A
16-06-14, 05:54 PM
Nice buy, where was that from?
The tray? Off ebay lad!
Ah nice. I never seen Nova panels on there...
Johnny A
18-06-14, 08:11 PM
Update:
For some reason I didn't take any pictures of the battery tray de-rot which is weird considering it took several hours! It was a real mess and I ended up cutting most of the tray out completely! I found a more hidden rot but thankfully its all gone now :)
Here is the fun part for me - I fitted one of my new wheels along with the wishbone, tie bar, hub and coilover body (no main spring). I then used a trolley jack to simulate the ride height I wanted:
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xfp1/t1.0-9/10418362_10154199477375214_4465876011108177087_n.j pg
I was so chuffed (still am), the wheel is the perfect size!
Wheel to coilover adjuster distance is 2mm:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/10417508_10154199477800214_831754303868483672_n.jp g
Lock to lock the modifications I did to the inner arches mean there is no rubbing!
With camber at the top mount set to maximum negative there is litterally buckets of room between the alloy and the outer arch:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpa1/t1.0-9/10462615_10154199478050214_4274846398186609046_n.j pg
There is a lot of camber though, around 3 degrees:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xfp1/t1.0-9/10306474_10154199477430214_300986779464411355_n.jp g
But here is the annoying part, these are labelled 'Ultra low'... it seems me and Gaz have a difference of opinion on what ultra low actually means:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10488405_10154199477770214_5665616410743730505_n.j pg
Yes the "Ultra" low coilover is touching the bump stop! Here is the actual ride height:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10310978_10154199477915214_4365913924717300129_n.j pg
Bare in mind the saloon arches are 10mm higher than hatchback versions, even so when I compared the image to SEF's image with the Leda coilovers fully depressed there is approximately only 20-25mm extra lowering to be had - that's pathetic really.
Anyways I am going for this ride height which means lengthening the turrets by as much as I can get away with, there are some other concerns which are wishbone angle:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-xap1/t1.0-9/10460733_10154199477595214_8052311645527248029_n.j pg
Steering rack angle too but this is an easy fix, also its borderline whether the driveshafts will foul the chassis rail, as seen with this picture taken through the CV joint hole:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-xfp1/t1.0-9/10421541_10154199478065214_3954605112166110315_n.j pg
The new battery tray is more or less ready to be welded in place, however the massive hole offers extra light to enter the cabin - this makes working on the EPAS column easier to I opted to hold back on welding in the tray for now.
After a lot more measuring, cutting and grinding I ended up with this:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10351101_10154199478135214_7420688900865659878_n.j pg
After the left-right distance was done based on many measurements and compensated for 'feel' and centralisation on the new wider Carlton digi dash I tweaked the angle and the bracket was in place :D
Notice I marked out the area that needs cutting on the dashboard, tomorrow I will do this, brace up the bracket and bolt the column on. Can't wait!
gary_126
18-06-14, 08:47 PM
great update as ever! Your fairly cracking on with this. New wheels look brilliant!
The shaft hitting the chassis leg isn't a nice noise :(
Johnny A
19-06-14, 07:46 PM
Update:
The EPAS column got it's final position tweaks today:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/10492154_10154203869475214_651752928548751759_n.jp g?oh=212724906f91ab433dad08523d997be6&oe=54135AA8
The dash gets cut then put in place:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-xpf1/l/t1.0-9/10462837_10154203869580214_4064383661524868801_n.j pg
What I see when sitting in the drivers seat:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10458079_10154203869955214_6032956558354778464_n.j pg
Perfect!
https://scontent-b-lhr.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10345835_10154203869995214_4758395306083547967_n.j pg
With all the checks I am very happy with the location and angle of the column, the linkage fouls a plate on the pedal box that has a stop rubber and the brake light switch on it. Both these will need to be relocated but it's not a big deal! I welded the top bracket on fully and cooked up a bracket for the rear of the column. I then removed the column and pedal box, at this stage it was time to weld in the new battery tray.
I started cleaning up the metal but something had been bugging me - the holes for the accelerator cable and bonnet catch cable. Some rust had formed and thinned the top of the area out, it was borderline but I decided to replace it anyway:
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xfp1/t1.0-9/10478151_10154203870215214_4725378755111620824_n.j pg
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xaf1/t1.0-9/10371652_10154203870525214_8014989644225724347_n.j pg
Welded in:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpa1/t1.0-9/10444532_10154203870580214_3256510177682347832_n.j pg
Johnny A
19-06-14, 07:59 PM
Oh also I looked into correcting the side-effects of the large suspension drop:
Driveshaft angle, wishbone angle and steering rack angle.
The wishbone angle is not a massive concern right now and can easily be corrected at a later date, the driveshaft angle will need to be looked at with the engine in. The steering rack arms need to be straight or bump steer will be killer, I have seen people raise the steering rack itself and it's something I considered. However having forked out for brand new bulkhead insulation I didn't like the idea of hacking it up with the rack in a different position. In fact the best was to fix the issue is to run the tie rod ends upside down, this gives me two options - spherical bearing tie rod ends OR cut and weld the hub carriers to flip the conical hole. Decisions decisions!
Vlietje
19-06-14, 08:37 PM
John, are you not fitting/welding OEM spec reinforcement rings on top of the suspension turrets?
Johnny A
19-06-14, 09:16 PM
John, are you not fitting/welding OEM spec reinforcement rings on top of the suspension turrets?
Using those Aristo ones, they are similar and will be welded in for extra strength
Not sure if you know this or if its been mentioned but late corsa B knuckles straighten the wishbone by about 10mm, not huge amount but every little counts
Johnny A
19-06-14, 10:13 PM
Not sure if you know this or if its been mentioned but late corsa B knuckles straighten the wishbone by about 10mm, not huge amount but every little counts
Yeah I did, have a set coming :)
Johnny A
23-06-14, 10:13 PM
Update:
The new battery tray went in today, not a fun job but I got it all done!
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/10455162_10154219960550214_8385150815518552024_n.j pg
This little curved panel is needed for the EPAS motor inside the cabin:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xfa1/t1.0-9/10455358_10154219960605214_2008511831136067050_n.j pg
I am not sure if stitch welding the bay was needed for the derv... did it anyway:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xfp1/t1.0-9/10349863_10154219960935214_7924638797429282106_n.j pg
bazzap8389
24-06-14, 12:12 AM
Good work :thumb:
Johnny A
24-06-14, 07:25 PM
So you're down the unit, you go outside for a pee and come back to find the entire front end has fallen off!
https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10494863_10154223421535214_8504128718335598708_n.j pg
Picture inside the O/S chassis rail showing the engine mount:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10426609_10154223420730214_7744971060459482792_n.j pg
Weldings all done on the O/S now: (apart from the turret extensions)
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/10446648_10154223420825214_4818744984737252911_n.j pg
N/S gets attacked with a blow torch and scraper, will wire brush the rest off tomorrow (hateful job):
https://scontent-b-lhr.xx.fbcdn.net/hphotos-xap1/l/t1.0-9/10446708_10154223421695214_3619816672709031048_n.j pg
Loving what you've done. Great work on the battery tray.
Danhart
26-06-14, 05:56 PM
Great work mate! I stitch welded my bay, isn't worth the risk of it pulling apart I thought.
Johnny A
26-06-14, 08:13 PM
More welding:
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10426827_10154231787170214_5255216220590093036_n.j pg
Totally shocked there is no rust hiding here:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10464095_10154231787225214_180154438386297840_n.jp g
More wheel porn:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/10492256_10154231788220214_7465381598118776474_n.j pg?oh=3eab9c019ca15f63494397e024090e75&oe=540E9EA6&__gda__=1411057227_cc5a84569a3f255616c8b4c9fa02e0a 9
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/10441902_10154231788445214_6357847678507539148_n.j pg
**** load more welding:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xaf1/t1.0-9/10462497_10154231788560214_6866525519550859083_n.j pg
I got one side all done before the welder bottle died:
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10484033_10154231788735214_240586244911180207_n.jp g
gary_126
28-06-14, 08:37 AM
love the new wheels, even in gold they look good!
Johnny A
28-06-14, 08:58 PM
Update:
My favorite purchase this week:
https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xpf1/v/t1.0-9/10485013_10154239073705214_1530645359646828920_n.j pg?oh=949824a6d48e92a048c267a34ad4d8ad&oe=5430DBF1&__gda__=1411813518_0a69eeaf5741f9a6811e605bd1f7215 2
Armed with a new bottle of welding gas I finished welding up the new front end and started work on the lengthened turrets, I chopped the top off the top of the turret and seamed on the strengthening plate:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-xfa1/t1.0-9/10488124_10154239073925214_1799060663993661213_n.j pg
I had acquired some 40mm wide steel strips to use:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10420350_10154239073590214_8496071048201986838_n.j pg
Top is tacked back on:
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/983700_10154239074175214_8638487333552485174_n.jpg
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/10511296_10154239074300214_5294269819569299916_n.j pg
This is the fun part! I refitted the suspension and wheel to check fitment... and to perv over the lows! First up I lowered the suspension until the wheel fouled on something, I made it to the top of the inner arch skin:
https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10478224_10154239074590214_703686024980135884_n.jp g
At this drop (which I estimate to be around 140mm) there is around 10mm to the bump stop.
Looks like this with the front arch in place:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-xfp1/t1.0-9/10418952_10154239074765214_7708056702357697027_n.j pg
This is where I am aiming for as before, with 40mm of shocker travel before the bump stop:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10444447_10154239075010214_1784741110616657974_n.j pg
https://scontent-a-lhr.xx.fbcdn.net/hphotos-xap1/t1.0-9/10501875_10154239075150214_7032918854506346069_n.j pg
Its porn!
https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpa1/t1.0-9/10155646_10154239075460214_6478084246152640448_n.j pg
With the drop set I checked steering rack alignment (running the rod ends upside-down will make them level out), bottom arm alignment (needs 60mm added to the bottom of the hub to level the wishbones out) and finally the clearance when turning the wheels (the inner chassis rail needs a small tweak and the outer arch rolled).
Next up was the dreaded bonnet, I really did not like the idea of bonnet bulges or raising the back up like the scene kids. So I started hacking and praying:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-xpa1/t1.0-9/10445973_10154239075905214_1285541217169838936_n.j pg
I placed the bonnet on top and found this:
https://scontent-b-lhr.xx.fbcdn.net/hphotos-xpa1/t1.0-9/10409547_10154239076205214_5675443266916458068_n.j pg
The bonnet it perfectly level with the panel, but on the untouched side:
https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10486508_10154239076345214_125588200556045232_n.jp g
5mm lower! I stuck my head inside the bay and saw the top mount securing nut closest to the wing was propping the bonnet up.
To correct this issue I tweaked the top turret plate shaving 1mm off it and welded it on followed by the bulkhead top section:
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-xpf1/v/t1.0-9/10425039_10154239076545214_1836114657923718100_n.j pg?oh=3ae05ab545063137d3676395797ee5c5&oe=5430FF86&__gda__=1410200825_422201c96970bd06788ebc053454372 0
https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpa1/t1.0-9/10484787_10154239076675214_9178188721811078296_n.j pg
Messy right now but it's all sorted, if the bonnet still catches I will trim the thread and nut down a tad but I doubt I will need to.
dgbnova#1
28-06-14, 09:28 PM
Just spot on as usual mate did not expect anything other than super low after the Carlton
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