Toms Nova Rally Car Build

[tomfromdelmonte]

Greetings.

This is my first proper post so ill give you guys a bit of background on me before i talk about the project. I learned to drive as a teenager in my girlfriends nova SR (around about 1998). After this i had about 4 or 5 novas and would not even consider driving anything else until my mid 20s when i started driving honda preludes. From the age of about 18-23 i worked as a welder fabricator and always dreamed about building and driving a rally prepped nova. I bought a wide arched shell with a rollcage but never even got round to picking up because i didnt have a garage and the place i was going to store it fell through. Then i managed to get my workplace to let me keep a stripped out nova at work but the reality was that i didnt have any money and when i left that place the nova ended up going to the scrapyard. So, fast forward 10 years and i now have a fairly decent job working in London doing IT networking. I drive a 1.2 clio as a runabout and most importantly ive just bought a new house with a decent sized garage... awesome!

Managed to talk the wife into letting me have a little project although she still maintains that i will never finish it. Before i even start working on the nova i decided that i had to prepare a decent working space. I decided to deck out the roof space in my garage and use it for storage. I also decided to remove the railings that line my drive as in the future i anticipate having to keep another nova on the drive to use as a donor car and to add to that i would also like at some point to get a road going nova as a daily drive!

2 Weeks ago i bought an absolutely minter E-reg non-sunroof shell from a guy on here (stareso). Went down to Fareham and trailered it away back up to Gloucester. The shell had been in dry storage for 6 years and was like finding a rare jewel. Perfect base for a rally car!!! Anyway, here are some pics of the sh** state of my garage and driveway before i began tearing things apart lol:

http://i799.photobucket.com/albums/yy275/Tom_Mann/SAM_0209_zps0fc82ead.jpg (http://s799.photobucket.com/user/Tom_Mann/media/SAM_0209_zps0fc82ead.jpg.html)

http://i799.photobucket.com/albums/yy275/Tom_Mann/SAM_0212_zpsf5f8359d.jpg (http://s799.photobucket.com/user/Tom_Mann/media/SAM_0212_zpsf5f8359d.jpg.html)

http://i799.photobucket.com/albums/yy275/Tom_Mann/SAM_0223_zpsa8fb38b2.jpg (http://s799.photobucket.com/user/Tom_Mann/media/SAM_0223_zpsa8fb38b2.jpg.html)

http://i799.photobucket.com/albums/yy275/Tom_Mann/SAM_0214_zps03194e2a.jpg (http://s799.photobucket.com/user/Tom_Mann/media/SAM_0214_zps03194e2a.jpg.html)


A bit of angle grinding, Root pulling, digging, forking, cleaning, scraping and general grafting later.... We have a spacious driveway and a well-prepped clean work area for the nova:

http://i799.photobucket.com/albums/yy275/Tom_Mann/SAM_0221_zps5e9375fa.jpg (http://s799.photobucket.com/user/Tom_Mann/media/SAM_0221_zps5e9375fa.jpg.html)

http://i799.photobucket.com/albums/yy275/Tom_Mann/SAM_0231_zps597ee8ef.jpg (http://s799.photobucket.com/user/Tom_Mann/media/SAM_0231_zps597ee8ef.jpg.html)

http://i799.photobucket.com/albums/yy275/Tom_Mann/SAM_0237_zpsdc5f8671.jpg (http://s799.photobucket.com/user/Tom_Mann/media/SAM_0237_zpsdc5f8671.jpg.html)

http://i799.photobucket.com/albums/yy275/Tom_Mann/SAM_0238_zps1ed04de6.jpg (http://s799.photobucket.com/user/Tom_Mann/media/SAM_0238_zps1ed04de6.jpg.html)

http://i799.photobucket.com/albums/yy275/Tom_Mann/SAM_0241_zps0734d6d9.jpg (http://s799.photobucket.com/user/Tom_Mann/media/SAM_0241_zps0734d6d9.jpg.html)

Have a ordered a roll over jig, a harry hockley plating kit and a custom cages full weld-in cage. Tomorrow im going to a local welding suppliers to get some abrasive discs, welding gas, 0.6mm wire and some other consumables so i can get my mig welder working (purchased last week, not tried it yet). Ive also just bought a 150litre air compressor which im gong to put behind the garage in a little outhouse and pipe it into the garage in 13mm copper pipe.

Plans for the car are really just to get the shell seam welded and get the cage in. Cant really afford to get it shot-blasted so may hire one and do it myself in the garage. Have bought a 1.6 16v engine but am still considering dropping a 1.3 in it to begin with. I have a feeling i may exhaust my budget trying to tune the 1.6. Still kind of undecided about that!

The other alternative is that i end up buying a rally car that is already prepped and keep the shell as a spare since rally shells have a finite lifespan.

Looking forward to hearing peoples ideas and advice.

[lee303]

looks a great base, got to say though you i love the name of your welder manufacturer, lol, as for engine choice, if your going rallying i suppose the regs will be the first point of call...good luck with it anyway :beer:

[mk1nova_rich]

Glad to hear the shell was as described, I looked at the For Sale advert myself and thought it looked decent :) garage looks like it will be a nice place to work in as well :thumb:

Good luck with it pal, this is what I would love to do...the 16v will probably give more power per pound than a 1.3 ;)

[L14MNP]

ESAB FTW.

I like the plans, mate. Looks a very good shell, too.
So are you going to be competing in this Nova? As said, get a copy of the regs!

[novarally]

Hi Tom, good to see the project has kicked off.

Your garage is tall enough for a 2-post lift, probably not wide enough though. Shame.

Look forward to seeing progress.

All the best.

Colin

[Benn]

How did i not know of this Nova... Was in my town!

[chris gsi]

Looks like a great base for a project and it's nice to see another nova in gloucester as mine feels lonely

[tomfromdelmonte]

Just picked up the rollover jig in kit form ready to be welded up when i get back on Friday. Will hopefully get the shell on there this weekend. Also should be collecting the engine this weekend. Have got a copy of the msa regs and am currently looking into booking my BARS test for next month. woohoo!

[tomfromdelmonte]

Looks like a great base for a project and it's nice to see another nova in gloucester as mine feels lonely

I didnt know there were other novas in Gloucester! which part u live in ? im in Kingsway

[chris gsi]

I'm not far away from you I live in quedgeley

[tomfromdelmonte]

Had the day of work but didnt get any work done on the car today. Spent all day laying paving stones in a small area to the rear of the garage. This is where im gong to mount the 150 litre compressor so hopefully should get that piped up tomorrow so i can start spraying primer on the shell when i need to. Got a new torch liner and sorted out the wire feed on my welder. Going back to the welding shop first thing to get some 0.8mm wire to use for the cage and also for welding up the rollover jig. The goal for tomorrow is to get the compressor piped up (havent even tested it since i bought it last week to see if it works!) and also to get the car on the rollover jig.

Should then be ready to start prepping the car!!

So much work before ive even started. Sure it will be worth it though.

Have also sourced an F13 close ratio gear cluster, an MBE management system and a pair of twin 45s jeted for a 1.6 rally car. A guy is coming tomorrow to deliver the x16xe that i bought on ebay so things are coming together slowly. Oh yeah, and my MSA rally starter pack turned up today... Awesome.

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0257.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0257.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0258.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0258.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0251.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0251.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0254.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0254.jpg.html)

[tomfromdelmonte]

OK!!!!

So finally some work done on the car and also a rather important (to say the least) item turned up today... the engine. Spent most of the day drilling out spot welds. Also went to machine mart and spent 70 quid on tools and fittings for the compressor. Didnt get the jig built or the compressor piped up but am hoping to get both done tomorrow. My spot weld drill-bit is completely shagged now.

Pics from today:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0259.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0259.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0267.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0267.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0268.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0268.jpg.html)

how many spot welds? looottttttssssss

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0270.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0270.jpg.html)

Jason helping daddy:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0278.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0278.jpg.html)

The beast:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0279.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0279.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0273.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0273.jpg.html)

Hopefully get some stuff done tomorrow... going to get up a 6 and get in the garage start welding up the jig while the missus is sleeping (and hence unable to whinge lol)

[Spudly]

If that compressor is perm mounted there (looks to be outside aswell) you may want to box it in/build a mini shed over it so it doesnt freeze come winter!

My mates is in the corner of his unit and that freezes up during winter as it gets damn cold in there, and it can cause damage to it!

[mk1nova_rich]

Progressing nicely mate :thumb: you will need a pack of spot weld drills lol

[faker]

Looking forward to following your progress Tom. Shell looks like its in great shape.

[tomfromdelmonte]

Well the weekend has almost been and gone and i am absolutely knackered! been in the garage almost the whole weekend doing bits and pieces. Got the Jig welded up which was a bit of a mission and also got the compressor plumbed in and tested. Been up at 6.30 sat and sunday and in the garage scraping off seam sealer (because its quiet and doesnt wakeup the neighbours).

Pics from yesterday and today:

Me vs. seam sealer
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0283.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0283.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0284.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0284.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0285.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0285.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0286.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0286.jpg.html)

Compressor piped up complete with pressure regulator and water separator:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0290.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0290.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0291.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0291.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0289.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0289.jpg.html)

Welding up the jig:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0292.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0292.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0294.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0294.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0296.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0296.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0299.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0299.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0302.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0302.jpg.html)

Decided i need a workbench of sorts, going to but a metal top on it for welding stuff. Also got a bench grinder because they are useful:
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0305.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0305.jpg.html)

Ready to be lifted onto the jig:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0307.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0307.jpg.html)

So im back off to London all week for work but next weekend the plan is to get the shell seam welded and sort out a couple of rust patches i came across. There is also a rather worrying bit of corrosion on the back lip that runs along the boot. It looks like someone has painted over it in the past. Am concerned that i may have to replace the panel but wont know how bad it is until ive taken the paint off and gone back to good metal.

Cage should be here next week. Awesome!

[tomfromdelmonte]

Got up at 5am on Saturday and pegged it over to Wales and got some rally nova bits off a top Welsh fella. MBE management system, polybushed anti roll bar, strengthened bottom arms with hockley uniballs and also these puppies:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0331.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0331.jpg.html)

Also managed to get some quality time in the garage and also got a bit of seam welding done.

I could see on the rear boot lip the paint was different which suggested someone has treated this area at some point. I had to take off the paint to see what was going on underneath. I also took off the bumper bracket supports so i could get into the corners and sort out some little rust patches. I then welded them onto little plates amd put them back in their original positions. Im not even going to try seam welding the bootlip as there is way too much sealer in there and the welds would just be ****e.

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0321.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0321.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0322.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0322.jpg.html)

whoops! over-cooked it...
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0325.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0325.jpg.html)

surfaces prepped for seam welding:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0316.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0316.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0309.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0309.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0312.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0312.jpg.html)

let the welding commence!

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0313.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0313.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0315.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0315.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0328.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0328.jpg.html)

Shell ready to go on the rolllover jig:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0338.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0338.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0337.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0337.jpg.html)

Enlisted the help of some neighbours, and now we're in business!


http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0339.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0339.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0342.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0342.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0341.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0341.jpg.html)

So now im on call for a week, hopefully next weekend will be quiet and ill have a chance to get some work done on the shell. I also have the whole of the week after booked as holiday and the plan is to blitz the shell. I am getting a shot blaster and im going to blast the shell myself, at least the bits of it that need blasting anyway. Hoping to get the underneath welding up and undersealed aswell as getting the cage in and maybe give the whole thing a coat of primer by the end of that week. Ill also be fabricating a dolly for when it comes off the jig. At around the same time im going to have to finalise a decision on the color scheme. Im torn between either white (works replica!) or black with a white interior. Kind of like the idea of this car being a works replica.

[gary_126]

Great prep work on the garage, you seem to be pretty well kitted out all ready. Nice project :D

[tomfromdelmonte]

Yep, spent the last 3 weeks doing more work and spending more money on tools/workspace. Preparation is very important so i guess its a good investment.

[kenny_afh]

I have to echo gary comments, ive been patiently waiting for welding pics as I knew fine they would be good just going by your approach to having the right equipment and space to work. welding looks really good, you've not lost your skills! really looking forward to seeing this progress. I would advise you to get the hole swagers/dimple dies off ebay and make up gusset plates for the cage with the pressed holes, they do work and tidy the whole job up brilliantly. other than that just keep the photos coming, going to enjoy this!

[A11VXL]

Great work so far, really good result with the shell it's looks to be in great condition. I'm going to enjoy following this one.

[tomfromdelmonte]

Got up at 5.30 a.m on Saturday and got straight in the garage to start scraping all the underseal off the car. Jobs like this are a pain in the a55 but at least it does give you a chance to go over every little nook and crannie and pick out ay bits of rust that need treating, so thats what i did. Got pretty much all of the sealer off and then took most of it back to bright metal with a knotted wire wheel. I then start welding up the seams and fitting the plates from the strengthening kit. Pics:

Scraping!

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0390.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0390.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0363.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0363.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0362.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0362.jpg.html)

After some wire wheel action the welding begins:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0368.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0368.jpg.html)


http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0369.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0369.jpg.html)

Strengthening kit (only 3 of about 10 parts welded in so far):

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0386.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0386.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0377.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0377.jpg.html)

Welded up:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0380.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0380.jpg.html)

Welds approved by the quality inspector:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0379.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0379.jpg.html)

Gave all the finished areas a coat of por15. Great stuff:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0385.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0385.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0383.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0383.jpg.html)

Something cool turned up in the post from custom cages:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0366.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0366.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0365.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0365.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0392.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0392.jpg.html)

So there now follows a whole week off work where im going to try and blitz the car. If i can get the cage in by the end of the week ill be super happy. Jobs for tomorrow are to tidy up the rear of the underneath of the car. There is surface corrosion in several places so that will all get the prep n' ready/por 15 treatment. Weld in the rest of the strengthening kit and finish off the seam welding. There are some holes in the floor that need sorting out aswell. Once thats all done then on to the cage. :)

[gary_126]

welding looks superb!

[tomfromdelmonte]

So im off work at the moment and had some cool stuff turn up in the post:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0396.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0396.jpg.html)

But ive had to get a couple of jobs ticked off my to-do list before working on the car. Neighbours are complaining about my driveway so had to make it look like i was doing something with it. Started laying the stones to make enough space for some more cars:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0415.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0415.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0416.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0416.jpg.html)

Ok so now ive made my back suitably sore. Time for some work on the rally monster!!! The strengthing kit is almost done. Just have the 2 large plates left to weld into the bay. The seam welding is also almost complete. Ive finished the rear and the underneath and the interior. Again i just have the engine bay left to do. Have bought a shot blaster on ebay so im waiting for that to turn up before i tackle it. Going to see a fabrication shop tomorrow and get a quote to have some plate bent up to strengthen the seat mounting points on the sills and also the gearbox tunnel in much the same way as the boys at smogsport have done theirs. Here are a few pics from today:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0403.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0403.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0405.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0405.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0408.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0408.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0412.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0412.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0413.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0413.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0410.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0410.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0411.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0411.jpg.html)

So plans for tomorrow are to try and get the seam welding done and dusted and started plating the few little bits of rust that need seeing to in the arches. There are some repairs to be done on the floor. Get the whole of the underside painted. And best of all - do a dry fit of the cage and weld in the mounting points. So, maybe tomorrow it will look like ive done lots!

[tomfromdelmonte]

Spent some time in the garage yesterday. Realised that im not really ready for a dry fit of the cage as i havent finished the seam welding and plating. I have however got round to the front/engine bay now so im almost complete with that side of things. Once thats done ill have to do the welding in the arches and a repair a few patches of rust.

So, some pics from yesterday:
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0420.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0420.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0421.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0421.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0422.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0422.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0423.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0423.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0424.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0424.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0425.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0425.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0426.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0426.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0427.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0427.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0428.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0428.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0429.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0429.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0430.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0430.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0431.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0431.jpg.html)

Hopefully more of the same today and see how we get on.

[scott.parker]

Nice build, good bit of time spent prepping there, quick question, is the roll over jig bought, or made?
I want one, but ive always wondered how good , stable they are, and how you get the car up into the hight it needs to be to use it..
Cheers.

[8valve-craig]

Im very impressed. Really enjoying this build, well done.

Can sympathise regarding the sore back, i took a week off my project recently to do some concreting. It put me out of action for a few days.

Keep it up, such a laborious task you are doing.

[Benn]

Lovely welding.

[tomfromdelmonte]

Scott the jig was bought in kit form from ebay. It cost about £160 and was a worthwhile investment. Getting the car on there was easy, it took 3 people to do it. the shell doesnt weigh very much so we bolted the brackets on and had the jig sat with the legs spread wide while the shell was on the floor. We then lifted the ack end up and put a crate underneath to keep it up. Then we lifted the front and bought the legs to together on the jig and bolted on the cross piece that sets the height. Thats 2 people holding up the shell and one person bolting the jig together. Then we repeated at the back. Pretty easy really. Its very stable, Im confident it could take the weight of the cage aswell and probably a person in there too. I can roll it round 360 degrees with one arm and lock it in position with the other. All in all a pretty good bit of kit and absolutely essential if you are going to be doing work where you need to get all over the car.

[tomfromdelmonte]

Thanks Ben and Craig, doing all this welding and fab work has really been a great experience for me. Ive had these skills since my 20s when i worked as a welder/fabricator but havent used them for a long long time as i work in IT now. Its pretty cool to know that its still there. When i go in my garage now the smell reminds me of the shop where i used to work. Stuck in the past? me? rebuilding a nova? surely not! lol.

[BigRuss]

Nice work so far....

Those top mount plates need to be completely seam welded inner and outer diameters though..

Why have you removed the upper part of the bulkhead? You now have no heaters in the car, a nightmare with the wiper linkage and have taken 1 litre out of your engine cooling system for no reason? you now need a heated screen and those carbs fly in under the bonnet on the small block xe engines..

Keep up the good work though, any questions just ask, its best to ask rather than fly in..

Russell

[tomfromdelmonte]

Hi Russ, thanks for the advice. This is my first time building a rally car and tbh i dont know too much about what im doing! the metalwork and fabrication is ok but the working parts are something i may need help/advice with.

Carried on with the welding and plating today, still not quite ready for the cage though - maybe tomorrow :)

Have had a hangover all day so that is my excuse lol. Here are some pics:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0441.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0441.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0437.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0437.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0444.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0444.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0445.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0445.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0446.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0446.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0448.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0448.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0449.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0449.jpg.html)

dodgy weld on there, seam wasnt clean enough. Going to re-do it tomorrow.

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0451.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0451.jpg.html)

So more of the same tomorrow and the end is definintely in sight. Have 1 more plate to put on and then a bit of seam welding/rust repair to do. Desperate to get my hands on that damn roll cage!

[Slippy]

Good stuff mate keep the updates coming

[tomfromdelmonte]

Need to get the work done first!

[scott.parker]

Scott the jig was bought in kit form from ebay. It cost about £160 and was a worthwhile investment. Getting the car on there was easy, it took 3 people to do it. the shell doesnt weigh very much so we bolted the brackets on and had the jig sat with the legs spread wide while the shell was on the floor. We then lifted the ack end up and put a crate underneath to keep it up. Then we lifted the front and bought the legs to together on the jig and bolted on the cross piece that sets the height. Thats 2 people holding up the shell and one person bolting the jig together. Then we repeated at the back. Pretty easy really. Its very stable, Im confident it could take the weight of the cage aswell and probably a person in there too. I can roll it round 360 degrees with one arm and lock it in position with the other. All in all a pretty good bit of kit and absolutely essential if you are going to be doing work where you need to get all over the car.

Cheers, brilliantly explained, so you think the car needs all the interior/glass out to use it?

[Rickyb]

loving this your doing a top job :thumb:

[tomfromdelmonte]

Scott, you could probably leave all that stuff in. Just make sure the jig is welded up nice and strong!

[dionbee]

Project is looking awsome fella. keep up the good work, Will be keeping my eye on this one! :) Just to second what you said with the Jig aswell, I've got the same one here. And weve had it on with doors, Tailgate, Bonnet, Bumpers axle and front suspension and a person in the car and it was perfectly stable. I'm very confident in the strength of mine.

Dion!

[tomfromdelmonte]

Spent some time grafting today. Pretty hard when you are also looking after a 3 year old. I tried to put him in the car with a laptop and season 1 of Ax Men (he likes to see trees falling down)... that worked for about half an hour until he started screaming that he wanted to come and 'help daddy' which basically means getting in the way and running off and hiding all my tools in obscure locations (washing machine, fridge, toilet, etc).

Started tackling the annoying little jobs that ive been putting off. Few patches if rust to be repaired. One on the front drivers side wheel arch and one on the passenger side rear arch. also noticed a bit on one of the turrets so i decided to weld a plate on there just to strengthen it up as the corrosion was on an area where it is only single thickness. Managed to get 2 of the arches finished and seam welded and painted up too. Looks pretty nice and feels good knowing i wont have to come back to that area of the car until im ready to put some shiny bits in there lol.

Pics from today:

suspension turret:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0452.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0452.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0453.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0453.jpg.html)

Corrosion on front wheel arch.. cut it out and put some new sheet in. Never turned my welder down to 1 before!

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0454.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0454.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0455.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0455.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0456.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0456.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0457.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0457.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0458.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0458.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0459.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0459.jpg.html)

Nasty bit on the rear arch. Its triple thickness sheet so i took it off layer by layer to figure out how much was bad.

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0461.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0461.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0462.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0462.jpg.html)

Got back to good metal. Treated it with prep 'n ready and painted inside the chassis leg with por15. Waiting for it to dry before i weld in the new metal

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0466.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0466.jpg.html)

Seam welded:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0460.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0460.jpg.html)

and painted!

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0464.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0464.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0468.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0468.jpg.html)

The little lad is going to nursery tomorrow so i should have a good few hours to crack on with this. Its slow going but im confident that it will turn out well.

[kenny_afh]

You're doing an excellent job on this, perhaps not so good at the babysitting tho ;)

[tomfromdelmonte]

Cheers kenny! ive asked the nursery for extra days this week so i can crack on with the car. My wife and parents are both out of the country at the moment so childcare is all on me at the moment.

[Nova Joyed]

Loving this thread Tom. I will be starting a Nova rally car build in the near future and this thread shows that a quality job can be done without having to pay someone else to do it. Can't wait to get started on mine!

[tomfromdelmonte]

So i was supposed to have all day today to work on the car. Had to go to a job interview this morning which went on til about 1 and then i had errands to run like getting a gas refill for the welder and also my halogen light blew the bulb so had to replace that too. Only ended up getting 3 hours in the garage before i had to go and pick up my lad from nursery. Got a few bits done today. Carried on repairing the rear arch that had corrosion on it.

On with the first layer of steel:http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0472.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0472.jpg.html)

Welded up:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0474.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0474.jpg.html)

Give it a coat of rust proof and then cut another piece to go on top. the holes are so that i can puddle weld it aswell to get it to hold its shape.

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0476.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0476.jpg.html)

coated the inside face:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0479.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0479.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0480.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0480.jpg.html)

Slit down the middle so i can hammer it back to follow the contour of the suspension turret:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0481.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0481.jpg.html)

Hammered it flush with the piece behind and then welded in the holes to hold it there before welding up the slit.

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0482.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0482.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0483.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0483.jpg.html)

Welded the inside diameter of the turret tops. Thanks Russell!

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0477.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0477.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0478.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0478.jpg.html)

Going to tack in the cage mounting points tomorrow so prepped the areas:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0484.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0484.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0485.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0485.jpg.html)

The fabrication shop said my bits should be ready tomorrow so i may well be cutting out the centre tunnel and welding in a 1.5mm channel. Also have some strengthening plated being made up for the seat moutning points. Tomorrow should be an interesting day. Parents are back from holiday on wednesday so may be able to persuade them to take the little monster off my hands so i can crack on with the rally machine. Fingers crossed!

[tomfromdelmonte]

Hi, thanks for the compliment. As for building a rally car, i can tell you its been a great experience so far. Not sure if i would want to repeat it though!

[tomfromdelmonte]

Been a busy day! started with a trip to the fab shop to pick up some bits. I had some plate bent up to reinforce the seat rail mounting points on the sills and also had a channel bent up to replace the gear tunnel in much the same way as the boys at smogsport did theirs. Anyway, didnt get time to do either of those jobs today! replaced the metal where the old seat rails used to be, it got pretty f**ked up when i drilled out the spot welds so ive cut in new metal on both sides. Here are the pics:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0487.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0487.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0488.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0488.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0489.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0489.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0491.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0491.jpg.html)

And the other side got the same treatment:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0493.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0493.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0494.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0494.jpg.html)

Finished off the seam welding in the engine bay and also the welding on the 2 big strengthening plates. Getting the hang of this now!

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0506.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0506.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0503.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0503.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0504.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0504.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0507.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0507.jpg.html)

And the moment ive definitely been waiting for. Started welding in the cage mounting points!!! before i welded them up i did offer up the main hoop and A pillar bars to make sure i was happy with the positions of everything. Starting to look like it might just be a rally car one day:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0496.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0496.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0497.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0497.jpg.html)

Welded up:
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0500.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0500.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0501.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0501.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0498.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0498.jpg.html)

Had a few deliveries today. A shotblaster, sparco seat and mounts, corsa gear linkage. The fab shop are making up my seat rails and and brackets ready for tomorrow so ill pick those up and think about getting those welded in too, a bit of a pain in the ass cuz it means putting the seat in the car to try and get the position right. Have also got the channel which needs to go in.

So to summarise the next couple of jobs: Fit centre channel, seat rails and harness points welded in, shotblast engine bay, weld up the cage mounting points, give EVERYTHING a coat of etch primer...

Start fitting the cage

Its finally coming together!

[dionbee]

Car's looking top mate. Welding is awsome fair play! Can't wait to see the weld-in cage, one thing I regret not fitting to mine. Hope all goes to plan with the fitting for you, Keep us updated.

Dion!

[tomfromdelmonte]

No pics today but i do have seat rails, mounting brackets and harness plates to weld in tomorrow. Neighbours are complanining about the noise when i use the angle grinder.. They mentioned environmental health... ****ing ****s!!!

The only time they ever talk to me is when they want to complain about something. Miserable CNUTS!

[Benn]

Very nice welding, like what you've done for the cage floor. And neighbours can be like that, i stop at 8pm and dont start till 10am.

[tomfromdelmonte]

Been on a mad mission to try and get all this fabrication work finished. Have promised my moaning neighbours that it is nearly finished. Did the job today that i wasnt looking forward to cuz i knew it would involve a lot of hammering and general noisyness! - the centre tunnel.

So i started the day with some straight forward stuff. Got the seating position marked so i could weld the seat rail reinforcement plates in the right place. Also fabricated some brackets for the seats too:
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0509.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0509.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0508.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0508.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0510.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0510.jpg.html)

Screw in place to locate the captive nut which is then welded. Going to cut these off at 50mm and weld to the seat rails.. the seat mounts then screw into the nut.

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0511.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0511.jpg.html)

Seat rail re-inforcement plates welded in :

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0513.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0513.jpg.html)

Rust patch in the battery tray repaired:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0512.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0512.jpg.html)

Didnt take many photos of this cuz i was too busy grafting! it was a bloody nightmare but i got it in eventually:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0515.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0515.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0516.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0516.jpg.html)

Seat rails in tomorrow and finish off the centre tunnel. It needs some re-inforcement at the joints. Also have the harness mounting plates to weld in, not a massive job. Will need to spray the underneath again and also finish the rear arches. The plan is to then give the interior and engine bay a coat of primer before getting to work fitting the roll cage. Drawing up a design for a dolly with castors for when the car is ready to come off the rollover jig (hopefully Monday). I have another week off so may still be able to get everything done.

[dionbee]

some skills mate.. Fair play! What is the main reason for remaking the tunnel? is it just for having the exhaust mounted higher up? Keep up the good work.

Dion!

[tomfromdelmonte]

Hi Dion, the reason for replacing the tunnel is simply for strength. The seat rails mount to it and the original tunnel was only 1mm thick tops (it might be less!). The piece that i cut out was pretty damn flimsy. The piece that i welded in was 2mm thick, a bit overkill perhaps but at least its not going anywhere!

[tomfromdelmonte]

Just as a note, i got the idea from the smogsport nova.

[tomfromdelmonte]

Been busy today, super busy!

Wasnt completely happy with the work i did yesterday so i spent a good few hours putting it right. So after much cutting, banging, heating, banging and more banging...

I ended up with this:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0517.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0517.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0518.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0518.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0519.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0519.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0520.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0520.jpg.html)

If anyone else every thinks about doing this.. DONT USE 2MM STEEL!!! its way too hard to work with. 1.5 would have been perfect.

Finished the other rear arch.. this is the one that had the large section of rust cut out and replaced with new metal:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0523.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0523.jpg.html)

And finally got round to installing the seat rails and then i ran out of time and had to go meet my parents for diner and pick up my little lad:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0524.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0524.jpg.html)

Next job is to finish off the seat rails. Weld in the harness mounting plates and then get some primer on the bloody shell!!

Then ill be ready for some rollcage action. Oh yeahhhhhh

[tomfromdelmonte]

So todays work was to get the seat rails and harness mounting points done. I got the FIA approved plates from JJCraceandrally.com, welded them to the outside and also plated the mounting area on the inside (for the crutch strap mounts but not for the lap strap mounts). The shoulder straps will mount to the roll cage. All in all a pretty good day. Things are looking alright and tomorrow im going to start prepping for paint.

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0528.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0528.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0526.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0526.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0525.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0525.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0531.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0531.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0530.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0530.jpg.html)

About ready for some primer id say:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0532.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0532.jpg.html)

[gary_126]

Your fairly cracking on with this, nice work!

[tomfromdelmonte]

Cheers pal! Am just dying to get that cage in there so it actually looks like a rally car.


Your fairly cracking on with this, nice work!

[tomfromdelmonte]

Started fitting the cage today. My god what a pain in the ass! nothing seemed to be the right length and i had to fettle the **** out of some pieces to get a decent fit. To be fair though my mate had warned me that when you get the cage thats how it would be lol. Did a fit with the diagonals and door bars to make sure i was happy with everything before welding up the main hoop and A pillar bars. I need to cut some holes in the floorpan and get get some ratchet straps. I will pull the legs in and drop the whole cage through the holes in the floor so i can weld over the tops. Once that is done i will weld the cage onto the mounting feet and weld in the door bars, rear diagonals and front triangulation etc. I thought this would be a really fun and exciting part of the build but in all honesty it has been stressful and bloody hard work! a couple of the gaps where the tubes fitted together were too big to do a continuous weld and the result is not the prettiest. I am however pleased with the overall result and im pretty sure it will all look pukka once the whole lot is in. I have been using 0.8mm wire but think i will change back to 0.6 to get some cleaner looking welds in the visible areas.

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0535.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0535.jpg.html)

Using the dash bar here just to spread the legs of the main hoop as they point in and dont sit properly on the mounts:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0536.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0536.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0537.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0537.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0538.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0538.jpg.html)
Going to re-do the right-hand weld as the wire feed on my welder crapped out while i was doing this. Im super paranoid about the scrutineer saying the welds dont look tidy enough.
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0540.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0540.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0542.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0542.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0539.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0539.jpg.html)

Got a busy day tomorrow so not sure if ill have much time to work on the car but Tuesday im hoping the get the cage mostly completed.

[dgbnova#1]

Looks good mate welds look fine to me and good work on the tunnel (although like u said 2mm is waywith eavy to work but its going nowhere now is it).

Have you done a sample for sending of for fia tests as that's the important part, I've seen cages with far worse welding pass and yours look spot on and neat to be fair. Do you need to cut holes to drop the cage down can you not get over enough just strapping an puting it on the floor that's all I do?

[tomfromdelmonte]

Cheers dgb, I havent welded up the sample yet. Its on the list of jobs for this week. I havent tried dropping the cage yet as i dont have straps but if i can get over the top without cutting holes in the floor then ill be happy as that sounds like a real pain in the ass!

[Benn]

Cage looks good, is the door bar not really high?

[tomfromdelmonte]

Hi Benn. Yes and no. It is high but i can confirm it is meant to be like that! the cage came with a cd of about 40 photos from custom cages showing completed nova cages. In the pics the door bars meet the main hoop exactly level with the top of the air vent hole in the shell (where that plastic air vent goes in the door gap). The geartunnel brace and rear stays and door bars all meet the main hoop at this same point. Here are some pics from the custom cages cd:
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/DSCF0017.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/DSCF0017.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/DSCF0024.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/DSCF0024.jpg.html)

[tomfromdelmonte]

Hi Benn,

These pics are from the Custom Cages CD that came with the cage:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/DSCF0024.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/DSCF0024.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/DSCF0017.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/DSCF0017.jpg.html)

[tomfromdelmonte]

Hi Benn,

These pics are from the Custom Cages CD that came with the cage:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/DSCF0024.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/DSCF0024.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/DSCF0017.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/DSCF0017.jpg.html)

[novadave24]

love that cage if you don't mind me asking how much was it ?

[Alex J]

cracking on fast!!

[tomfromdelmonte]

Dave it was about 850 all in with the vat and delivery. 2 week lead time. Weight of the cage is 47kg. If you go T45 it will be 40kg... for the difference in price though you'd be better off cutting down on Big macs and kebabs if you want to save 7 kilos.

[tomfromdelmonte]

Spent most of the day working on getting the cage sorted. First step was to drop the cage off the sills and weld over the tops. Just about managed it although there were some really weird angles and had to hold the torch in some unusual positions. Used ratchet straps to pull the legs in:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0544.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0544.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0545.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0545.jpg.html)

After doing that i popped off to Wickes and bought some timber to use to spread the legs back onto the spreader plates. 3 were easy but the last one was a total beeyatch. It was sitting 10mm high above the plate and even with all my weight on it i couldnt bring it down. Enter ratchet straps again, perfect!

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0550.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0550.jpg.html)

X door bars look the shizzle:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0551.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0551.jpg.html)

Main diagonal in:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0554.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0554.jpg.html)

How i left it this evening:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0556.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0556.jpg.html)

Its slow going because almost every single piece needs fettling to get a decent fit. If the fit isnt good then the welds end up looking like bird poo. Should get it finished tomorrow and then ill start getting the shell ready for a bit of paint. Ordered a Kevlar fuel tank guard for it, need to source a petrol tank from somewhere (anyone?). Be about time to start getting the rear beam re-furbed and built up with the golf disks/calipers and bilstein suspension. I also got polybush kit for it.

One of things that is really bugging me at the moment is the fuel tank set up. The feed/return lines are a no brainer but im not sure how im going to connect the tank to the filler. I think i may need some bits here. Probably need to go through all the stuff that came with the car, i just threw it all in the roof space, not even entirely sure what ive actually got!

Starting to look like a rally car at last. thank f** for that!

Been watching Ari Vatenen videos on youtube... really need to get out in this car and do some rallying. Got to keep my eye on the prize and no get bogged down by details. The aim is to go rallying in a nova that i built.. not just to build a rally car.

[gary_126]

Id say your making brilliant progress, its really time consuming stuff.

[tomfromdelmonte]

I had no idea it would be so much work to get where i am now. Youre right... very time consuming. Especially with the cage. If you dont get a decent fit with the parts then you cant do a continuous weld and it ends up looking ****e!

[dgbnova#1]

Yep just fetal away as you will be pissed if u rush and no going back once uve done it and ure not happy. Looks Spot on to me and no extra holes in the floor!

Start mine soon I hope

[phunkynova]

I'll be keeping a eye on this. Looking good so far. :thumb:

[tomfromdelmonte]

Thanks for the comments guys, much appreciated. Well, another couple of hours in the garage today. Fettling away with the grinder and marker pen trying to make all these pieces fit together nicely. Welded up a few of the joints and ran out of welding gas at exactly 5.30pm so that was well timed. I should have the cage done tomorrow. hoping that the front triangulation isnt too hard to get in. Super happy at the moment. Been working my ass off and it never really looks much different from day to day however in the last 2 days it has transformed in my eyes from a basic shell to a full on rally monster in the making. So here are some pics from today:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0558.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0558.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0557.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0557.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0559.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0559.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0565.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0565.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0567.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0567.jpg.html)

The car is a lot harder to move around in now and ive lost count of the number of times i bumped my head on the roof or on one of the bars today. Hoping to get the welding wrapped up tomorrow and need to get some paint on there as there is a lot of bare metal.

[tomfromdelmonte]

Made some more headway with the rally car today. The cage is now 100% welded up and complete. Guy from the council turned up today and said the neighbours have complained about the noise. He was actually pretty cool, i showed him what i was doing and made a point of telling him that i actually work in London and under normal circumstances im only home 2 days a week. Added to this i only work on the car between the hours of 1 and 6 pm as my neighbour works nights (wasnt him who complained). He said that since i wasnt doing it during unsocial hours and that it was only a temporary thing that the council would not be taking any action. He asked me to give him a ring if i thought it would take longer to complete. He seemed really interested in the car and said he always wanted to built a catheram 7 kit car but didnt have the technical skills. So.. happy about that. The point is that almost all of the fabrication is now complete and the grinding/hammering etc is more or less finished. ****S!!!! Cant wait til ive got a tuned XE in there, then ill give them something to complain about lol.

Anyway, moving swiftly on. Pics from today:
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0575.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0575.jpg.html)

Only parts of the whole bloody kit that fitted staright away, not complaining though!

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0574.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0574.jpg.html)

Cut open the wings to get a weld all the way around:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0579.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0579.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0578.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0578.jpg.html)

Repaired inner skin:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0583.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0583.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0581.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0581.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0584.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0584.jpg.html)


brace welded in:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0587.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0587.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0593.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0593.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0590.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0590.jpg.html)

Plans for tomorrow is to just generally tidy up and prepare for some paint. Going to paint the underside again with rust proof paint and paint the inside with primer. Need to get my hands on a fuel tank!

[scott.parker]

Thats a serious cage dude, love it..

[tomfromdelmonte]

Scott, its going to be a serious car!

[chris gsi]

The cage looks awesome. I can't believe how quick it's coming on and by the look of your welding skills it's a shame you work with computers now:thumb:

[bazzap8389]

Same cage I just bought :)

hats off to you mate, some really good work going on there :thumb:

[Benn]

Lovely welding on the cage.

[tomfromdelmonte]

Got some primer on the shell interior at last. Looks pukka! im not that great when it come to spray painting. Really just threw the paint on to be fair but then it is a rally car so im not going to lose any sleep over that!

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0605.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0605.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0606.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0606.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0607.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0607.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0608.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0608.jpg.html)

Going to pick up a petrol tank tomorrow. The kevlar tank guard arrived today so im hoping that tomorrow i can those fitted and give the underside a last coat of anti rust paint and then ill start to thin kabout getting it off the jig onto some axle stands or something in preparation for building up the steering suspension and getting it rolling.

A small victory in many ways.

[_Jake]

Nice work on the cage, good looken welding!

[gary_126]

This will be finished before the months out lol

[Slippy]

Just as a note, i got the idea from the smogsport nova.

:thumb:

Good progress mate whats next ???

I put a few update pics on FB https://www.facebook.com/media/set/?set=a.559640877385344.151070.555815244434574&type=1

[dgbnova#1]

:thumb:

Good progress mate whats next ???

I put a few update pics on FB https://www.facebook.com/media/set/?set=a.559640877385344.151070.555815244434574&type=1


Some lovely work there mate lots of good ideas will be referred to that for ideas looks spot on.

[tomfromdelmonte]

Next is think about what im going to do next!

Got the tank and kevlar guard to be fitted. Need to get some plumbing stuff sorted as its nearly time to throw in the brake and fuel lines. Have to cut the holes for the internal corsa shifter, fabricate a handbrake bracket, paint the underside again as ive done a lot of welding since the first coat and burned a lot of paint off. The car needs to come off the jig and the interior also needs a coat of gloss white at some point.

I have the golf rear disc conversion to build up (need the discs machined), need to source a corsa b epas column and a quaife quickrack. Protec bias box and brake line kit has been bought and should be here next week. Rear suspension and bushes are here and ready to fit. Definitely got plenty to be getting on with...

So, today i primered the engine bay and front of the car....

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0613.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0613.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0614.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0614.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0619.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0619.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0615.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0615.jpg.html)

Unfortunately my break from work comes to an end tomorrow and ill be back in London. Must say im quite happy to have the cage in and the shell with some paint on it. Thats pretty much the point i wanted to be at before i went back to work. It will be slow gong from here on out but im sure ill get there eventually.

Needs wheels, lol.

[greene94]

looks good. cant wait to see it finished

[dionbee]

Honestly looking superb matey. Some quick work gone into this! Makes me want to get another shell and atart again. Keep it up. Chosen a colour yet? :)

Dion!

[tomfromdelmonte]

Thanks for all the comments. I do appreciate the encouragement. Dion i think its going to be white and im going to try and get some decals like the original works novas (red, blue, yellow stripes and mobil 1 decals etc). So today i was mostly on childcare duties and cleaning the house/wifes car before she comes back from overseas. Did managed to find a spare hour or two to get a few jobs done on the car. I had some little 'coins' to weld in over the drain holes in the floor. Once that was done i flipped the car over on the jib and set about giving the underneath a good going over with the grinder/wirewheel before spraying on some paint. I also put silicon sealant over a couple of small holes and around where i welded the disc. The petrol tank i bought yesterday was left overnight and i was hoping the petrol would all evaporate but there was still a little bit left in it this morning so i couldnt start wirebrushing that and cleaning it up (sparks and petrol are a bad mix fyi). I did however give the filler neck a good seeing to and a coat of paint. It was proper manky before although i didnt get a pic of it. So here are some pics from today:

Wirebrushed and sprayed with Frosts prep n' ready (converts rust to something else and leaves a layer of zinc oxide to prevent further rust, great stuff)
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0620.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0620.jpg.html)

painted
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0633.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0633.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0623.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0623.jpg.html)

before:
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0629.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0629.jpg.html)

after:
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0630.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0630.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0632.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0632.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0634.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0634.jpg.html)

Needs sorting out and some aeroquip lines!
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0621.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0621.jpg.html)

Well thats it for this week. Im back to London in the morning. Will try and order some bits during the week so that i can crack on at the weekend. Want to get the tank and guard in with the fuel lines at least attached to bulkhead connectors. Then the car can come off the jig and onto axl stands ready for the build. Have decided the fuel pumps will be mounted in a box behind the drivers seat.

[mk1nova_rich]

Cracking work mate, not had a look for a while...well done on doing everything yourself :) as for your neighbours, don't they have anything better to do than complain?? Fair enough if you were grinding away through the night lol

A quick pointer in case you didn't already know...there is a 12/13mm breather pipe that comes off the end of the tank, through the chassis rail and up to the top of the filler neck. Don't forget to fit it to the tank before you fit it, then poke the hose through the hole in the chassis rail as you lift the tank into place. Then cut to length before fastening the hose to the top of the filler neck :)

Also it may be worth cable tieing some mudflap material around the bottom of the filler neck to provide some protection as it sits fairly exposed in the bottom of the wheel arch :thumb:

[tomfromdelmonte]

Cheers Rich, thats exactly the info i was looking for.

[mk1nova_rich]

Its impossible to fit the breather hose once the tank is in place so its extremely frustrating when you have your tank and guard in place with fuel lines connected up and have to take them off again ;)

Its the left outlet of those two closest to the camera in your pic I'm referring to, the small one with the long pipe just vents to atmosphere - it normally just clips around the edge of the tank

[tomfromdelmonte]

So ive been doing a bit of research with help from some of the nice people on here. It looks like jobs for this weekend are going to to be getting the fuel tank in. Ive got a good idea of the fittings i need and how it all goes together so i can order that up tomorrow when im at home. Going to be undercoating the shell with 3m sealant. There appears to be 2 types, a 1 part sealer and a 2 part sealer which appears to be double the price. The price for the 2 part sealer on the 3m website is 17 quid for a 250ml bag where as a litre of the 1 part stuff is about 4 quid on ebay. Anyone know anything about this?!

Going to need some help here. Does anybody know how the rear suspension connects to the shell? I know how the beam bolts on (can u get new bolts?) but im not sure what i need in terms of bolts/washers etc for the shocks. I have some bilstein gpA shocks and a polyurethane bush kit and that is it. What else do i need? Also i dont have the plastic cover which goes over the rams, do i need this? cheers.

[Slippy]

Good progress mate

Paul might well be able to shed some light on the 3M stuff Bob (Snr Swan AVO) uses te mix in a bag expensive stuff and rates it, thats what will be going on the escort and our shell.

[mk1nova_rich]

The plastic dust covers aren't essential but strongly advised, some off a pair of standard shocks may fit.

Bolt the shocks to be the beam, then jack the beam up and guide the threaded ram tops through the holes in the shell. Don't forget to fit bump stops first, then from inside the boot fit the top mount bushes then there is a large washer and a nut til approx 10mm of thread is showing past the nut

Fit your springs carefully during the jacking up procedure

[tomfromdelmonte]

thanks for the info Rich. I dont have any of those parts. Ive just got the shocks and Polyurethane bushes. do you know where the best place to source the other bits is?

[scott.parker]

Try find someone breaking a standard nova on here mate, ask for the rear socks with all the parts you need.
Cheapest easiest way imo.

[tomfromdelmonte]

Did a test fit of the seats today and they were way too high!!!! even without a helmet on my head was touching the roof bar, not good. I may have to cut the seat rails off tomorrow and weld them as low down to the floor as i can go. Bugger!!!! Wirebrushed and painted the fuel tank today and installed the filler neck. Some stuff turned up in the post.

Fire in the disco!

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0642.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0642.jpg.html)

I ordered this:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/sabelt6point.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/sabelt6point.jpg.html)

But what i got in the post was this:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/2013-11-07123741.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/2013-11-07123741.jpg.html)

Phoned up and told them the crutch strap was missing and the guy said i was confused!!!! i described what i had in front of me and he said that was how a 6 point was supposed to be. I had to send photos before they admitted that there was definitely a part missing. Im sure this was a one-off genuine mistake. Lets hope the other parts turn up tomorrow!

Got a busy day tomorrow but im hoping to get some of the fuel lines sorted, slam the seat rails (makes it sound easy!) and get the underside sprayed with underseal.

[mk1nova_rich]

Who did you order the harnesses from?

When we welded the seat rails in my old Nova we literally had them just high enough off the floor to get a seam of weld under the rail. I'm 6'3" by the way, I'm guessing you are fairly tall too...?!

[dionbee]

Looking forward to some more progress. I'm sure you'll enjoy the spending on all the shiny bits for the car! :)
Just a quick idea for you, I'm 6'3" and I normally have trouble with seats being high up in rally cars and this is how I've fitted mine:

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/7149_10151702897615070_2029349149_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/7149_10151702897615070_2029349149_n.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/992964_10151702898170070_825783020_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/992964_10151702898170070_825783020_n.jpg.html)

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1044697_10151738800840070_173512192_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/1044697_10151738800840070_173512192_n.jpg.html)

I've got plenty of room and I reckon I could have a helmet on no problem as well, Plus I run XL wider seats as well and there's still plenty of room..

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/999471_10151883749485070_1679993457_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/999471_10151883749485070_1679993457_n.jpg.html)

hope this helps.

Dion!

[tomfromdelmonte]

Yep, definitely my bad on this one. If you are 6ft or over then your seat rails should be as low as you can go. I didnt know this. Im bang on 6ft btw.

Not sure if i can cut the rails out and still have them long enough to be re-usable. Hopefully the angle of the centre tunnel will help me here as putting them lower will mean the rail needs to be shorter.

Dion those pics are really helpful. Are those the fuel send/return lines? what did you do with the pumps? i have planned to mount them behind the drivers seat.
Rich it was Peter Llloyd Rallying. The guy was a bit funny on the phone, very reluctant to accept that they hadnt sent me the complete harness but once i had sent pics they were fine.

[dionbee]

The tubes on mine have been fitted by drilling through the tunnel and Sill and feeding the tube through, Welding around it and then placing the spreader and welding around that aswell. and then grinding flush on outside and welding another plate over underneath the tunnel if that makes sense? That's the only way I'd do it to be honest rather than just welding the faces on.

Yes, They are send and return for the fuel although the Return is blanked at the front (I've just fitted it incase I want to go down the injection route in a few yrs and it'd save me re-routing everything then.

My fuel pump is behind the drivers seat on the rear floor (where rear seat goes) because my seat is so far back and i have a bar running side to side at the bottom of the cage like so:

http://i146.photobucket.com/albums/r254/dionbee93/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/560819_10151842457985070_824743760_n.jpg (http://s146.photobucket.com/user/dionbee93/media/Facebook/Nova%20Road%20Rally%20%20Endurance%20Build/560819_10151842457985070_824743760_n.jpg.html)

So mine is fitted here: (Remember aswell if you are going to be rallying it You'll need it to be in a sealed box with a pipe running from the box through the bottom of the car outside incase of leakages etc. this is a £8 ammunition box welded some brackets on and painted black/carbon wrapped and does the job perfectly for a fraction of a pump box. Also quietens the pump noise a little! (Picture is before the lines were fitted, just drilled and tight rubber grommets fitted)

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

Hope it helps.

Dion!

[scott.parker]

Fire extinguisher is a very overlooked important thing to have, especially a plumbed in one.

[tomfromdelmonte]

Yep! not sure if you need a plumbed in one for the msa regs but everyone seems to have one. Ive also got a handheld one to go under the nav seat although i didnt take a pic. Anyway, today has been pretty hectic. The wife went out for a couple of hours so that was my cue to get in the garage and set about sorting out those bloody seat rails. I also drilled the holes to make way for the internal shifter, it was getting late so i left cutting the whole piece out til tomorrow. I also managed to get a GSI rear bumper of a local guy on ebay for £20. My head is in a bit of a funny place right now with this project because im kind of between two phases. The fabrication/shell and the build proper. Been kind of struggling to focus and figure out what the next job is. Planning things out on paper helps i guess. The way i see it now i need to finish the rails and then spray the underneath with the 3M sealer that turned up yesterday (im going for the black stuff in the 1 litre cans, its pretty cheap). Once thats done ill be able to fit the tank. I dont have any fuel pipes yet and i dont know if i can get them from pirtek tomorrow. Once those 2 jobs are done then i will have to give the interior/engine bay another coat of primer or two and then a coat of white gloss topcoat. At this point i will take the car off the jig and put it on axle stands ready to start running in the fuel/brake lines.

Here are pics from today?

Goodbye old seat rails... a real **** to get out!!!! had to finish off with a hacksaw of all things!
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0643.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0643.jpg.html)

As per the build manual .. added a couple of mm for clearance, holes are 29mm hole centres 100mm apart
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0647.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0647.jpg.html)

Reinforcement plates got a bit f***d up taking the rails out so put on another layer for strength
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0644.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0644.jpg.html)

SLAMMED!
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0645.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0645.jpg.html)

Can see how much lower they are now, almost touching the floor so def cant go any lower!
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0646.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0646.jpg.html)

[tomfromdelmonte]

Pretty happy right now. Got a couple of jobs done today and i feel like im on track with this now. Got up at 4.30 and drove down to dorset to collect some alloy wheels that i won on ebay for 48 quid (not bad at 12 quid a wheel!).

Got the seat rails nicely welded in and double checked the seating position. Welded in rear harness mounting points to the rear strut brace. Cut the hole for the internal gear shift. Welded an M10 washer to each of the lower arm mounting points as per the competition build manual. Gave the whole shell several coats of primer and sprayed the underneath with 3M underseal. I can safely say that now im ready to start building the damn thing! Fit the tank/guard and then take it off the jig and onto axle stands. Also ready to coat the interior and engine bay with diamond white topcoat. Thats tomorrows job. Ok, so pics from today:

just a nice pic of the shell as it was this morning when i started work
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0649.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0649.jpg.html)

Harness mounts:
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0652.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0652.jpg.html)

M10 Washer
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0653.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0653.jpg.html)

Seat rails pretty damn solid (i hope)
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0651.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0651.jpg.html)

Centre tunnel brace (forgot to weld it in, found it in my toolbox)
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0655.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0655.jpg.html)

Hmmm, what's for dinner?
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0657.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0657.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0659.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0659.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0661.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0661.jpg.html)

Got alloys now, awesome!
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0662.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0662.jpg.html)

[Vlietje]

You've got some skills boy! Great work!!

[tomfromdelmonte]

Thanks Vlietje! i havent done anything like this for a very long time. Its the first time ive picked up a welder for about 10 years! The one thing i have got plenty of is motivation. whenever someone has asked me "what car would you have if you could have any car?" ive always said ' a nova rally car' so this is like a dream come true for me.

Anyways, today i put some topcoat on the engine bay and car interior. The colour is Ford Diamond White, its a gloss white cellulose paint and it was pretty easy to spray. I have to keep reminding myself this is a rally car so the paintjob isnt really a big deal, so to be fair i just threw the damn stuff on! I also painted white primer over the black 3M underseal as i think a white underneath looks cleaner.

Did a test fit of the tank and guard to try and figure out in my head how im going to connect the fuel lines and how much i need in preparation for next weekend which is when i'll start running in fuel/brake lines and fitting the tank. The kevlar guard fits the tank ok but one of the tank straps is miles off being able to close so will be some work required to make that fit.

Here are pics from today:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0673.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0673.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0676.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0676.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0682.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0682.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0683.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0683.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0684.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0684.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0685.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0685.jpg.html)

So thats it for this week. Going to try and source fuel pump and hose/fittings this week aswell as a box to mount the pump in. Going to copy Dionbee i think and use an ammo box.

[chris gsi]

I can't believe how quick your building the car. And the cage looks awesome if you need tyres fitting give me a shout and I can fit them at work for you:thumb:

[dionbee]

As said above.. Some Seriously Quick work going into this! don't worry I haven't forgot about the line pictures for you..


Dion!

[Peredur]

Awesome work, Makes me want to get on with mine! Seriously want a weld in cage now

[mk1nova_rich]

Cracking work mate :thumb: you may have to manipulate (bend) the tank straps to fit. I had the same guard fitted and a few mins of straightening and bending reshaped it so it fitted snug and reached the stud

[tomfromdelmonte]

Thanks guys!

Chris i may take you up on that.

Just as an update ive ordered the braided fuel hose and fittings. Not bloody cheap!

Hopefully got everything i need now to permanently install the tank and run the lines to the pump and then up to the bulkhead. I have already bought a Black Diamond brake hose kit and a Protec bias box from a nice chap on here (SimonTW) so i can run the brake and fire extinguisher lines at the same time. Do need a hydraulic handbrake though and i think ill probably go for a vertical fly-off type as ive seen one fitted to the ex-Bernard Munster works nova (F163BEC) so if its good enough for him then its good enough for me!

[dionbee]

Do you remember what size the fuel breather was? I need to replace mine next weekend. The one from the Fuel filler neck to the tank. (goes through the chassis rail iirc)

Dion!

[mk1nova_rich]

Its 12 or 13mm

[dionbee]

Cheers + Repped.

Dion

[dgbnova#1]

Ye it's 12mm fuel pipe should be able to get it from a motor factor but not to common out of the 6 local here only 1 could get it for me and watch they don't offload water pipe as the pipe u need as one tryed to do to me

[chris gsi]

Tom I work at the vauxhall dealership down the road from you so it's not a problem

[tomfromdelmonte]

Dion the internal diameter is 10mm. You can also use an-8 pipe with a jubilee clip as it has an internal diamter of 11mm. I took my filler pipe down to pirtek the other day and they tried a few hoses on it and that was the one that fitted.

[dionbee]

Aaah, No way? I've just bought a length of 12mm off ebay. Gutted!Dion

[tomfromdelmonte]

That might do for you if the internal diameter is big enough.

[dionbee]

The one I've ordered is a 12mm Internal diameter. haha!

Dion.

[tomfromdelmonte]

Does anyone happen to know what size/length the lower arm to chassis bolt is?

[paul james]

Does anyone happen to know what size/length the lower arm to chassis bolt is?

M10 x 76mm (with 40mm of threaded section on the proper bolts)

[Vlietje]

11086131 2000581 screw,hex.hd.,m10 x 76,control arm to underbody (nls.- use 11086133 20 00 973) 2

[tomfromdelmonte]

Thanks guys! where did u get this information from? im looking for similar information regarding some of the suspension components like the bolts/washers for the rear shocks... do i have to use the vauxhall cup washers or can i substitute some standard type flat washers

[tomfromdelmonte]

Well, spent most of today pottering about with no real sense of purpose! Pirtek didnt have the hoses i need to do my fuel tank but they did point me towards a motorsport company at castle coombe race track , about half an hour away from me, who are open saturdays and stock pretty much everything i needed at competitive prices... RESULT!!

So, a quick trip down there and 100 notes later i have all the braided hose and a bits and pieces to get my tank on including a rollover valve for the 5mm breather.

Also got a bunch of rivnuts and pclips to do the fuel lines inside the car. Plus my Sabelt crutch straps turned up.

Oh.. and i have a steering wheel now lol. Pics tomorrow

[tomfromdelmonte]

So, what i thought would be a pottering about not doing much kind of day turned into a epic GTD (getting things done) session.

Ok job 1, fit the fuel tank. I removed the injection pump and ground down a hose fitting on my bench grinder to get the correct size fitting so that i could connect a straight piece of pipe to the strainer. The pipe i used is properly rated to be fully immersed in fuel without degradation. I then had a real nightmare with this stupid 13mm drill bit. There is a special technique to using it which is to put very little pressure on the drill. I put pressure on it and rather than drilling a hole it just ripped a big ****ing piece of metal out. Ended up with 6 holes when i wanted 2. Will be using rubber bungs here. Got hold of an ammo box to mount the fuel pump in (cheers Dion, excellent idea). Here are some pics. Gave the whole interior another topcoat and then a coat of 1k lacquer (used a whole litre). After that i managed to get the shell of the jig and on axle stands and tested some shiny bits... cuz from here on out its all about the shiny bits. YEAH!

modifed fuel pick up:
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0690.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0690.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0692.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0692.jpg.html)

******* 13mm drill bit from hell! made a mess.
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0698.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0698.jpg.html)

Breather pipe is on, no worries!
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0700.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0700.jpg.html)

The jig is gone. long live the jig!
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0713.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0713.jpg.html)

Shiny
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0705.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0705.jpg.html)

Looking like a rally car almost. Dry fit is good for Morale!
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0715.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0715.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0716.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0716.jpg.html)

So next week im going to run fuel lines/brake lines and try to sort the rear beam out.

I sat in the driver seat with the harness. Felt a strange mix of excitement and fear. I think this thing is going to be a real beast.

[Novasport]

Great progress, wish I could get this much work done on mine in that time.
Did you get chance to get those measurements?

[mk1nova_rich]

Looking good mate :)

[dionbee]

Looking good Tom! Some good progress being made, and looks to have a good shine on the paint. Time will fly now while bolting all these bits on..
Keep us updated.

Dion

[gary_126]

Ah the joys of drilling thin metal with big bits. one way it to keep increasing drill size by a mm or so, less chance of catching and tearing as you experienced. (I drilled my roof for a bee sting after paint with hss drills... nervous moment! lol)

Where will the fuel pump be mounted, rear footwell? Be interested to see how this works, as ive an in tank pump fitted to the same tank as yours, and had a lot of problems (as the multi point injection pump is tall, so every part has to be shortened so the strainer isn't squashed, but my pattern tank seems to be 10mm shallower aswell to make things worse)
So, thinking of doing what you have done, just not sure if it will work with the fuel being sucked a foot from the strainer.

Is that hose tail threaded into the std pipe?

[Mike]

Ah the joys of drilling thin metal with big bits. one way it to keep increasing drill size by a mm or so, less chance of catching and tearing as you experienced. (I drilled my roof for a bee sting after paint with hss drills... nervous moment! lol)


Centre punch where you wanna drill so the drill bit doesn't skip & slide around everywhere, spot drill it with something like a 3mm, then say 7mm then final size.

[dionbee]

Both you guys are correct, I used a 'step bit' to drill mine. Just making sure i was stopping at the correct size! Its the christmas tree shaped drill bits and goes up incrimentally in size by 1mm each time. Might be an idea if you've got a lot more to do mate.

Dion.

[gary_126]

yeah step drills are good, I just didn't have one.

[tomfromdelmonte]

Gary the hose tail is not threaded. Its just slightly larger than the standard pipe even though the ID is smaller. I ground it down on a bench grinder until it was an inteference it inside the std pipe. I was going to put a bit of weld on it but since it tapped in smartly with a hammer and feels rock solid i dont think it needs it.

I am going to mount the fuel pump (it will be a facet red top) behind the drivers seat in the footwell there. My understanding is that these pumps should be mounted as close to the tank as possible. This fits with what i know about pumps since the suction side is negative pressure (a vacuum) and these pumps are really designed for providing pressure on the discharge side.

Dion i got the ammo box like you suggested, a bargain at £8!!! will give it a coat of gloss black this weekend and bolt to it the floor with a facet pump inside.

[tomfromdelmonte]

Didnt have time for anything today so i just took some pics of some of the bits that are ready to go on the car. Had a sort through the bits in the roof void. Like a tw** i threw out the 2 front suspension struts cuz i thought i would have my bilstein fronts by now... which i havent. So that means i havent got the stuff i need to get it rolling, going to have to source some standard struts as i dont have the 600 quid i need to get the bilstein ones... bugger.

Did have a trip to the fastener shop to get new nuts and bolts for some of the stuff ive got and also painted my rear mk4 gti calipers. Oh yeah, and i also managed to get the discs machined down to 56.6mm for a tenner.. result!

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/2013-11-20083906.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/2013-11-20083906.jpg.html)

Hydraulic handbrake and protec bias box:
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0736.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0736.jpg.html)

Gear stick.. needs a white quaife style knob at least.. just need to find out what the thread is..
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0737.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0737.jpg.html)

Polybushed and strengthened bottom arms with hockley uniballs:
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0738.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0738.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0739.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0739.jpg.html)

Thats it for now. Hoping to get a big done tomorrow. Ive just got a pair of new mk2 front wings and a gsi bumper. Looking to get the rear beam refurbed tomorrow and run in the fuel/brake lines. fingers crossed.

[tomfromdelmonte]

btw if anyone has a pair of standard nova struts and springs pm me please.

[chris gsi]

I have a set in the garage you can have front and rear that are doing nothing but getting in the way

[tomfromdelmonte]

So, an update of sorts. Number of brake/fuel lines installed today = 0!!!!!

Got a bit carried away with wirebrushing, painting, etc. Had a good sort through the roof void and picked out a few bits. Managed to get some front struts (thanks Chris!) so i can get the chassis rolling. Stripped and painted the rear beam with hammerite (the expensive stuff). The polybushed bottom arms i got, one had a split in it so i welded that up and painted them along with the anti-roll bar and the pedal assembly. Fitted the bias box and steering column just to get them off the floor. Column will need to come out because its not a quick rack.

My kitchen has a floor mounted plinth heater which makes the kitchen like a bloody oven.. perfect for drying paint!!! Wife will be happy when she comes home lol.

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0741.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0741.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0742.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0742.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0744.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0744.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0746.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0746.jpg.html)

yes that is a kids bike, it was in the way so i 'dropped it in' as they say.
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0749.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0749.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0751.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0751.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0756.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0756.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0758.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0758.jpg.html)

Back to london tomorrow. See what happens next week. Hoping to get the rear beam on the car proper and get 4 wheels on her.

[greene94]

I have a corsa brake servo on my nova and it left me with a deadly brake what would the brake be like wit the brake bias box like?

[novarally]

I have a corsa brake servo on my nova and it left me with a deadly brake what would the brake be like wit the brake bias box like?

And in English?

[mk1nova_rich]

lollol ^^

Really starting to come together now mate, looks the part :)

[tomfromdelmonte]

Cheers Rich. The bumper will obviously be getting painted white and the glass in the tailgate will be getting replaced with polycarbonate. The whole car exterior will get painted after its rolling and this time i will try to do a bit more than simply throwing the paint on.

At the moment im after a mk2 front bumper, grill and headlights/indicators. So if anyone has any bits knocking around in the garage send me a pm please!

Lol @ Colin....

Greene94 - it will be great , get one.

[tomfromdelmonte]

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0752.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0752.jpg.html)

fuel pump box
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0743.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0743.jpg.html)

[tomfromdelmonte]

Can anyone advise on this:

Ive purchased an F13CR close ratio cluster and an F10 casing with a 4.2 final drive. Added to this ive just bought a quaife LSD from a guy on here.
Will this combination work together ok for my rally car doing single venue tarmac stuff initially?

Im looking at the budget ( or lack thereof) and i really cant afford a proper rally gearbox (the quaife ones) since they are a few thousand second hand even.

In addition to this ive been thinking about the engine. So far i have a fully rebuilt (although not modded) 1.6 16valve XE. A pair of twin 45s jetted for a 1.6xe rally engine. An MBE ignition system.

I dont have a massive amount to spend here so im thinking of just investing in cams, arp bolts, standard pistons machined with pockets to clear the cams and possibly head work depending on the price. Anyone have thoughts on this?

The rest of the car is pretty straightforward i think.

[mk1nova_rich]

Twin 45s sound good and for a rally engine are probably more suitable than 40s

What are you thinking cam-wise? Bear in mind the standard cams are actually pretty good on these engines so I would be tempted to see what you think before splashing out on aftermarket items :)

Oh and an F10 casing won't fit over the flywheel and starter motor on a 16v engine...you will need an F13/15

[tomfromdelmonte]

Thanks for the info Rich, i got the F10 for 25 quid and really just wanted the 4.2 FD out of it. I guess i could drop that into an F13.

[tomfromdelmonte]

I was thinking of trying either the bill falconer reground cams with shims or maybe the newman tarmac rally cams (the profiles on those look a bit wild). Not sure if the car would be undriveable with those cams.

[mk1nova_rich]

Yes it will go straight into an F13 casing no problem

If you have the budget for cams then go for it, as standard cams will obviously limit power potential - I just suggested it in the sense that if you were really tight for cash then money would have been better spent elsewhere :thumb:

[dionbee]

Car looks brilliant mate. I'm basically running the same spec box as you said..

F13CR box, 4.2 CWP and Plated LSD. And totally honest, It's transformed the car mate. Should be good in your car! :)

Keep up the good work buddy, Coming alond quickly.

Dion!

[tomfromdelmonte]

Just had a bit of a reality check....

I need to finish this car and get out rallying. I dont have endless supply of money to throw at tuning a 1.6xe.

Added to that i probably dont even have the skills to be able to drive it properly. The power should come later. What i need now is something cheap and fun to put in there and learn how to drive a rally car.

Going to put a 1.3 in there. Just need to get this finished at minimal cost from now on.

[wwinstanley]

How did you find painting the cage once it was welded in? Tricky?
Planning on a similar cage for my new rally build but dont know wether to paint it first and just repaint where i have welded once its in?

[tomfromdelmonte]

Painting the cage was pretty easy. There were a few funny angles and some parts of the cage didnt get as much paint as others. I painted it while it was on the jig so i could turn it on its side and stand in the *place where the door goes*.

I think you will be fine painting it inside the car

[wwinstanley]

Cool, got mine on the rollover jig at the moment so shoudnt be an issue. Cellulose paint seems fairly forgiving anyway so cant make too much of a pigs ear of it.
How far did you go with removing underseal? Iv got the majority off but some tight spots i am finding impossible to remove it.

[tomfromdelmonte]

Number 1 tool for removing the sealer is a blowtorch

You buy the torch for 15 quid off ebay and the propane bottles are about a fiver
1 bottle lasted me the whole job and is still half full.

when you heat up the sealer it goes super soft like butter and u can just wipe it off with a wirebrush...

[tomfromdelmonte]

just out of interest. How much have you budgeted for your build?

ive just totalled up my expenditure over the past 2 month and it was eye-watering.... i never imagined the costs involved.

[wwinstanley]

Will give that a go then, have been using paint stripper, paint scraper and a wire wheel on an air drill. It takes ages and is totally soul destroying haha

[dgbnova#1]

Wire wheel on a grinder wins every time not a wire cup though the one that looks like a disk is the one u want

[RallyMarshal]

yes that is a kids bike, it was in the way so i 'dropped it in' as they say.
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0749.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0749.jpg.html)


Are you planning on running the standard blower unit? If so, it has to be boxed in so to speak so there is a solid bulkhead between the engine bay and the blower unit.

Just wondering how you were going to seal the heater / blower?

With regards to your reality check - nothing wrong with a 1300 / 1400 8v engine. I have been running a 14NV block with 1400 big valve head. std pistons, Kent AST17 cam with solid lifters, ARP bolts and twin 40s on dizzy for the past 2 years in my Mk2 Astra. I do have a Quaife F20 box with 4.8 CWP which makes a big difference - especially a long 1st gear - but we won our class on the Jim Clark National in 2012, Rockingham in 2012 and Rally Barbados this year. Its been a good engine and was producing between 106bhp and 110bhp at the wheels during setup. Ive just had a 20SEH (2.0 8v engine) built which was fitted last weekend so going to see how that goes for a while now.

I do however think that if you can derestrict the breathing on a 1400 16v (with carbs, TBs or whatever) then add a set of ARPs I think a decent but otherwise std x14xe will produce more power than a modified 1400 8v that and is a better base to go from.

Paul..

[1396rally]

Can anyone advise on this:

Ive purchased an F13CR close ratio cluster and an F10 casing with a 4.2 final drive. Added to this ive just bought a quaife LSD from a guy on here.
Will this combination work together ok for my rally car doing single venue tarmac stuff initially?

Im looking at the budget ( or lack thereof) and i really cant afford a proper rally gearbox (the quaife ones) since they are a few thousand second hand even.

In addition to this ive been thinking about the engine. So far i have a fully rebuilt (although not modded) 1.6 16valve XE. A pair of twin 45s jetted for a 1.6xe rally engine. An MBE ignition system.

I dont have a massive amount to spend here so im thinking of just investing in cams, arp bolts, standard pistons machined with pockets to clear the cams and possibly head work depending on the price. Anyone have thoughts on this?

The rest of the car is pretty straightforward i think.

What events are you looking at doing?

I run a either a F13 CR cluster or a Quaife F10 SCCR cluster in an F10 casing with either a 4.2 or 4.5 CWP and a plate LSD. Either setup would be a good improvement over the standard gearing. You would want the 4.5 CWP for something more tight and twisty and the 4.2 for something more airfield like. If you can find a Quaife SCCR cluster then they are a step up again, as first is much taller (standard 1st gear with a 4.5 CWP is almost useless)

[wwinstanley]

just out of interest. How much have you budgeted for your build?

ive just totalled up my expenditure over the past 2 month and it was eye-watering.... i never imagined the costs involved.

I havnt really budgeted for my current build mate, I tend to just close my eyes to the money I have spent. Less painful that way haha!
But it would be difficult for me to work out as its sort of a cross between a build and a re-shell. I am essentially re-shelling my current rally car (which I threw into a granite wall at high speed) but uprating certain things as I go along, like a better cage etc. Everything else I can transfer from the old car.

[tomfromdelmonte]

wwinstanley...

if you have a nova rally car then you should really start a thread. Would really love to see some pics, even if it is battle-scarred.

I have done a breakdown of everything i spent on the car in the last 2 months and it has come to over 8000 pounds.

Ouch. It hasnt even got wheels on it yet.

[RallyMarshal]

Im sure I posted a reply yesterday on this thread but it hasnt appeared.




yes that is a kids bike, it was in the way so i 'dropped it in' as they say.
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0749.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0749.jpg.html)


Do you realise that you have to box the heater hole / blower in so that theres a solid bulkhead from the engine bay? Might be something you didnt know on your first build.

With regards to engines, I have run a Mk2 Astra with a 1400cc 8v for the past 2 years. Its a 14NV block, std pistons and rods, ARP bolts, a big valve 1300 head with Kent AST17 cam on solid lifters and twin 40s with dizzy. Nothing fancy, just well built and netted us 1st in class on 2012 Jim Clark National, 2012 Rockingham (and 19th overall) and 2013 Rally Barbados as well. Its around 106-110bhp at the wheels on the rolling road when setup. I do run a Quaife F20 SCCR box with 4.8CWP which brings it alive but the Astra is 960kg all up so not a lightweight car.

Ive just fitted a 20SEH 2000cc 8v engine on twin 45s with Kent AST31 cam on solid lifters, modified XE bottom end etc etc.. Rockingham in 2 weeks time so hope it will be as good.

Personally though, in your car, Id fit a std X14XE or X16XE with either throttle bodies or carbs on the inlet, std cams and head, ARP bolts for safety and an appropriate ECU. Will produce more power then an 8v but the engines are cheap to swap if there is an issue and is a batter base to start from.

Paul..

[wwinstanley]

wwinstanley...

if you have a nova rally car then you should really start a thread. Would really love to see some pics, even if it is battle-scarred.

I have done a breakdown of everything i spent on the car in the last 2 months and it has come to over 8000 pounds.

Ouch. It hasnt even got wheels on it yet.

I have been meaning to start one but havnt had chance, hopefully next few weeks i will start one up!
Think im well under your budget at the moment including the purchase of both cars!
Battle scarred is an understatement lol, you will see what i mean when the pics go up.

[tomfromdelmonte]

Start one now!!! i want to the car. Just take some pics, stick them on photobucket and them paste the links into your thread. SHouldnt take too long!

Its great motivation when you know other people are taking an interest in your project and getting ideas. Every time you finish a job on your car you want to document it and stick on there for other people to comment on or offer advice.

So whereabouts are you based and what sort of rallys have you already done?


I have been meaning to start one but havnt had chance, hopefully next few weeks i will start one up!
Think im well under your budget at the moment including the purchase of both cars!
Battle scarred is an understatement lol, you will see what i mean when the pics go up.

[wwinstanley]

Il try find some time to start one in the next few days then! Have done threads on other forums like when i had my Mini.
Im based in Jersey, Channel Islands. I started this year with a local navigational rally just in my road car, then In June it was L'etacq Attack which is a local single venue rally about 16 stages long, was seeded 38th of 39 to start and ended up with 25th overall and class win for up to 1400cc. Then was the Jersey Rally, seeded 64th of about 70 something cars. 8 afternoon stages went well, then onto the night stages, climbing up the ranks. penultimate stage of the night i was positioned 23rd and then walloped it into a wall, that was us out of the rally for sure.
Hoping to get my new car built for early next year so i can compete in some UK rallies as well as the ones over here. I have only money and time against me!!

[scott.parker]

Did you get my pm tom, let me know if them indercators are any use to you.
Scott

[TallDave]

Tom. This thread is something else, a rally shell prepared in just 3 months is remarkable, I've read others that have taken years, and several are yet to be completed even 4 or more years later... A true inspiration as to what can be achieved, your missus must be very understanding, though you still seem to be keeping up with your fatherly duties. Me I've had a car awaiting re-build for 3 years (the seats and belts are now out of date for stage rallying purposes, don't start me!), that said I have had to build a workshop down the bottom of my garden.
Anyway to my point, first I notice you welded seat belt mounts to the cages rear strut brace, I'm not too sure about how the scrutineer will view that method of fixing? I can say it would have been simpler to just remove the shoulder harness seat belt mountings and then just wrap the belts around the bar and re-threading them through the adjusters.
As a budding competitor I sort of assume that you are already a member of a local Motor Club, if not could I be so bold as to suggest you join one, in you location I'd suggest one of the clubs affiliated to the Cotswold Motorsport Group http://www.cmsg.co.uk/ . If you pick the right club you should be able to tap into some valuable expertise, you should also be able to consult an MSA Scrutineer in respect of those essential safety steps you need to go through, he/she should also be able to produce the Vehicle Log Book your car will require before you can start your first event.
True the logbook can be prepared by the scrutineer at your first event, but it can be embarrassing and expensive if the car doesn't comply the necessary regulations, ouch!

I look forward to your notes on building the disc braked rear beam, something on my very long to-do list, especially as the drums are acting as pivots on my home built rollover jig!
I will start my own thread soon, honest.

[gary_126]

As for the engine, personally id go for a 14xe, found in corsa b's and tigras mainly, plenty in scrap yards (as opposed to hunting for a 1.3 8v) That way when funds allow build a spare one cheap. With a powerbox inlet (can be made diy) and a decent exhaust should see 100bhp, or 120bhp on twin 40's, with the only real upgrades being arp con rod bolts, paddle clutch, steel idler rollers, and a fixed timing tensioner. So all quite cheap in the grand scheme of engine tuning (150bhp is achieveable from the likes of bill falconer) Also being 1400, keeps you in the lower class :D

[tomfromdelmonte]

Gary, ive already got a 16xe with a pair of twin 45s and an MBE management system. Im thinking of doing all the things u mentioned above plus getting the pistons machined (to accept hi lift cams) and putting a pair of rally cams in there. Its just for the price of the cams alone i could probably pick up a 1.3 rally engine. The other thing is i dont want to have too much power in the beginning, it makes learning harder.

Id rather have a low powered engine and push it to the limit. Im going to look into your suggestion a bit more as your're right the engines are much easier to get hold of and 100bhp should be more than enough to start with.

[tomfromdelmonte]

Does anyone know if it is possible to get a shorter 1st gear into a standard F13CR.. something closer to 2.6:1???

[Peredur]

F13 CR 1st gears are usually either 3.5:1 or 3.7:1
2.6 would be longer than standard.

Have a look at this link for ratios of standard 'boxes:

http://www.opel-infos.de/getriebe/f13_5.html

[gary_126]

Gary, ive already got a 16xe with a pair of twin 45s and an MBE management system. Im thinking of doing all the things u mentioned above plus getting the pistons machined (to accept hi lift cams) and putting a pair of rally cams in there. Its just for the price of the cams alone i could probably pick up a 1.3 rally engine. The other thing is i dont want to have too much power in the beginning, it makes learning harder.

Id rather have a low powered engine and push it to the limit. Im going to look into your suggestion a bit more as your're right the engines are much easier to get hold of and 100bhp should be more than enough to start with.

Ah well, id defo go for a 14xe, and fit your management and carbs (although 45's may be a bit big on a 1400?) All the reliability bits you will be putting on the 1400, will be a direct swap to the 1600, so makes sense.

[tomfromdelmonte]

does anyone kow what size/thread the bolts are that attach the rear shocks to the axle?

Could anyone also point me towards a resource for identifying parts like this.. thanks.

[scott.parker]

I cant be sure on the size, but would think m10-12?
Im sure someone on here must have a copy of the build manual for rally, but if not theres enough people with all the info mate, start an individual thread asking for the info.

Scott

[Iain]

17mm head so M10, and I'm sure I've used standard pitch bolts in these before. Vauxhall's parts catalogue EPC would be ideal to look up things like this if you can find a copy somewhere

[TallDave]

Tom. I've got a copy of the Nova Competition Build Guide if you want it, its in PDF format so I can email it to you if you like?

PM me with your email address if you want a copy.

Brilliant build by the way, rocket like progress, at this rate it''ll by on the road by Christmas...!

[mk1nova_rich]

I'm pretty sure the shock bolts are M8. I have a brand new one at home, maybe one day I'll find another!!

Now someone will tell me they are still available at Vauxhall lol

[TallDave]

Iain is correct, while mk1nova_rich isn't! Its definitely an M10 bolt 63mm long, but be careful as its 1.25mm pitch, get that wrong and it won't fit the captive nut. As a matter of interest the Bolts that fix the rear beam to the shell are also M10 x 1.25 bolts, this time 84mm long. the plain (unthreaded) part of the shank is 27 and 57 mm long respectively.

How do I know, got them in front of me with a thread gauge to hand...

Cheer :thumb:

[mk1nova_rich]

I do apologise lol you will find a lot of the suspension fixing bolts are fine threads

[tomfromdelmonte]

Awesome, thanks for that Dave! I've already got a copy of the build manual which has been a great help so far. The main issue now is budget and spare time. Not much chance of it being done by christmas but im hoping to get most stuff bar the engine and gearbox done by the new year.

[tomfromdelmonte]

Well, spent most of the day faffing about picking up parts etc etc. Had a passenger ride in another nova today (and a nice one at that!) which has really sparked my enthusiasm for getting this thing driveable!

So, didnt get much done except putting the pedals in and painting the bumper with primer. Did manage to collect a few parts including some astra gte ATE type calipers with grooved/vented discs and a quaife ATB diff.
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0766.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0766.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0765.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0765.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0764.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0764.jpg.html)

fuel please!
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0768.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0768.jpg.html)

traction please!
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0767.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0767.jpg.html)

slow down please!
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0760.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0760.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0762.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0762.jpg.html)

Going to get my 4.2 FD in the morning. Not sure how much time i will have to do jobs. Picked up the fittings for my hydraulic handbrake today. Got everything i need to run in the fuel and brake lines including the facet pump.

[Slippy]

Good work mate keep it going

[dionbee]

Looking good mate, looks like your having a good time bolting all the bits onto the shell.. Good luck with everythin, hope all goes to plan!

Dion

[tomfromdelmonte]

I was having a good time until i got bearing grease on my wifes rug. When she comes home tonight im gonna have to make myself scarce until she calms down. What the F*** was i thinking!?

[scott.parker]

lol new rug for Christmas?
Glad you got the indicators mate, hope they're good for what you need.

[tomfromdelmonte]

Well having survived a severe beating from my wife because of the carpet (and agreeing to rent the rug doctor for the 2nd time in a month) i did the only thing i could do to clear my head and figure out what to do next.. i tidied the garage.

I have accumulated a large collection of bits and now have a long list of jobs to do.

Here are just some pics from today, i didnt really do much except try to organise myself. I did however go to the local fab shop and have some sheet cut so i can make the gussets to go between the cage and the A/B pillars. Just need to trim then to shape and get a dimple die to cut out some holes. I also had to take my brake discs to a garage and have the bearing races pressed in with a hydraulic press as it just wasnt happening with the block and wood and a hammer. One place wanted £60 just to put the bearings in the disc... Errr, no thanks!! Managed to get it done for 28 quid in the end which was a bit steep but at least im good to go and i can build the beam up now.

Looks like i will have some newman tarmac rally cams on the way soon from a fellow forum member. Cool!

Went up to Neath at the weekend and picked up an F10 box so i can scavenge the 4.2 FD. If anyone (preferable local) has an F13 they want to let go off then send me a PM.

Anyways, i'll let the pictures do the talking.
Gussets in the making...
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0776.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0776.jpg.html)

Next job is fit this before the beam goes on
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0778.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0778.jpg.html)

mk4 gti rears
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0780.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0780.jpg.html)

GTE fronts
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0781.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0781.jpg.html)

bottom arms, hockly balljoints and ARB fitted :).. standard suspension until i find some bilstein coilovers
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0777.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0777.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0774.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0774.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0772.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0772.jpg.html)

Thats it for now. A coil spring compressor is also required so i can the hubs on.

[tomfromdelmonte]

Had to get up this morning at 3.45 and go to work. Am absolutely shattered.

Did a bit on the car. Bought a brand new rivet tool from ebay, put in 5 rivets with it and the bloody thing broke.... silverline tools, not impressed!

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0787.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0787.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0785.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0785.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0783.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0783.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0782.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0782.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0788.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0788.jpg.html)

Need sleep.. and possibly beer.

Made a ****ing major purchase today from Harry Hockly... :)

details when it turns up.

[mk1nova_rich]

Looking seriously cool now :cool:

[scott.parker]

Getting there mate, some good progress..

[tomfromdelmonte]

Been blessed by the gods of 'getting things done' today.

Ran in the fuel and brake lines and plumbed up the hydraulic handbrake. Had to modify the handbrake mechanism so it is less up right and leans forward more as my elbow was hitting the seat making it impossible to operate it properly. Took a lot of time to get the position right relative to the gear stick. Ultimately i will be modifying the gear lever so it sits about 3 inches higher. Fixed the mechanical fire extinguisher to its bracket.

Steering wheel position is f****g WAY off. Needs to be about 3" to the right and about 5-6" lower. Looks like ill be modifying the bracket and fabricating a different mount. There is a possibility that ill be sourcing a corsa b epas column so im holding on for that at the moment.

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0791.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0791.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0789.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0789.jpg.html)

I seemed to be suffering from a severe case of things not fitting properly. Tankguard was no exception, could no get the tank straps on (one was ok, one wasnt) so i cut the offending item off and welded on a M8 x 50 bolt. Perfect!

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0800.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0800.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0801.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0801.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0797.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0797.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0798.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0798.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0796.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0796.jpg.html)

HAd trouble with these flo-flex bushes. They dont fit. not impressed. Used a g-clamp to press em in. Still no good.
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0802.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0802.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0803.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0803.jpg.html)

Thats it for now. Roll on Saturday.

[scott.parker]

Silly question, did you offer it up to the beam swing arm to see if they will fit before putting them in? If there two big trim one down, use some grease, and i bleave a way to fit bushes is to get big sockets and put a bit of threaded bar, or very long bolt through the middle and another socket head, then a nut on the other end, you can then tighten the nut squeezing the bushes in, hope that makes sense?

[tomfromdelmonte]

Scott, after taking these photos i introduced one of the bushes to my friend Mr Stanley Knife. They get on very well and the bush now fits lol. I offered up the bushes to the chassis and they seemed ok. They are just way too tight. I did but a long bolt with some big washers on but it made no difference.

[mk1nova_rich]

A lot of people have had that same issue when fitting the Flo-flex beam pivot bushes - seems to be luck of the sraw as I bought a set and they fitted fine

[Mieran]

Put the floflex bushes in the bin and get some prorace ones off rally design

[tomfromdelmonte]

Mieran. You are not the first person to say that. Order = placed.

[novarally]

Had to get up this morning at 3.45 and go to work. Am absolutely shattered.

Did a bit on the car. Bought a brand new rivet tool from ebay, put in 5 rivets with it and the bloody thing broke.... silverline tools, not impressed!

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0787.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0787.jpg.html)



Need sleep.. and possibly beer.

Made a ****ing major purchase today from Harry Hockly... :)

details when it turns up.

In my opinion there is only one type of (manual) pop-rivet gun worth buying, and that's a Gesipa Flipper.

They're not cheap (£50-odd), but if you're doing a lot of rivetting they're priceless, and a lot less strain as well.

Or if you're feeling very well-off, the Gesipa Accubird is the toy to get - cordless battery powered. And about £500.

[tomfromdelmonte]

Colin, i bought the Gesipa yesterday :), was certainly an improvement!

[_Jake]

Loving the progress on this, you can come do mine afterwards if you want lol

[tomfromdelmonte]

So, a productive day i suppose. I have got the rear beam and stuff on and now can put wheels on her.
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0823.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0823.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0816.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0816.jpg.html)

Have come up against 2 problems though. The first is that with the golf discs and the nova stub axles on.. the wheels are right up against and literally touching the chassis. Not good and im not sure why this is. The VW/Vauxhall bearings are indentical as i have compared them to each other.

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0831.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0831.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0828.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0828.jpg.html)

where the inner bearing sits with the discs on:
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0822.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0822.jpg.html)

The other issue is that the golf caliper mounting brackets are too close to the discs to get the carriers on. I think i may need to turn the protec brackets round so they point the other way. Does anyone know the correct orientation for these? Have i got it right already but have a probem elsewhere?

Not sure is these 2 problems are related. It seems like the whole wheel/discs assembly needs to be 10mm further out on each side.

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0806.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0806.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0809.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0809.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0808.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0808.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0815.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0815.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0810.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0810.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0820.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0820.jpg.html)

Any advice very gratefully received!

[gary_126]

at a quick guess id swap the caliper carriers side to side (so the shoulders are on the inside of the car) Calipers should fit then. But as for the wheels sitting too far in im not sure, all looks correct.

[dionbee]

Car's looking well mate! Getting built up very quick now. I'd get some new bushes for the beam if I were you, They'll rip if they've been attacked with a knife!

Dion.

[scott.parker]

Not sure about the brakes, but might seam silly, did you try jacking the beam up to see how the wheels fitted if they were in a road hight position? Worth a look, but if its the same maybe theres a soacer/part missing, and this would solve the calipers and wheels..?

[tomfromdelmonte]

hey Dion. Yeah i did order some bushes from rallydesign on Thursday night. I hoped they would be here by the weekend but they didnt turn up and i was desperate to get the beam on and see what it looked like with wheels on. Glad i did cuz ive uncovered the issue with the calipers and wheel clearance so i can try to get that sorted for next week and also re-do the bushes at the same time.

I need a spacer plate to go between the caliper bracket and the stub axle to get the right gap between bracket and disc and also to get the wheels to stop fouling on the chassis. I took some measurements today and the whole thing is off by 18mm which is a HUGE amount. Im going to fire an email over to protec and see if they can offer any advice.

So anyway, only pics i took today were just a few more of the offending items ,,, oh yeah, and one of the recent purchases that turned up on friday ;-)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0838.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0838.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0841.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0841.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0846.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0846.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0817.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0817.jpg.html)

I'll see what i can sort out this week. Taking the stub axles to london so i have a spacer machined to space them out. I will weld the spacer onto the stub and also have the holes in the spacer tapped to match the stub axle (i.e. tapped from the stub axle side o the thread is continuous). Im not sure if there is another way of doing this but the biggest question is WTF! not sure what is causing this issue.

[_Jake]

Hockly front struts? :)

[tomfromdelmonte]

Yeah :)

Tarmac spec now but im getting the gravel springs aswell just incase i get the chance to do a bit in the forest

[therealnovaboy]

Are you sure you have the calliper mounts the right way round?

Can you put the left one on the right side and right on the left so that the bit that sticks out is on the inside rather than the outside. that might give you the 10mm you need.

Im not sure if this would work because the edge of the beam might hit the bracket.

[tomfromdelmonte]

Been pretty busy lately but have managed to get a good collection of bits going. Got a full set of polycarbonate windows from ACW motorsport plastics. full set of 15" gravel and full set of 15" tarmac rally tyres. Polyrace bushes to replace the badly fitting flo-flex ones on the rear beam.

Been exchanging emails with a Bristol graphics company called brizgraphics who have given me a great price to have all the decals made up to have the car looking the same as the original works novas. Looks like thats how ill be going with it.

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/vauxhall-nova-rally-6.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/vauxhall-nova-rally-6.jpg.html)

So, i started fitting the Corsa b epas column thinking it would be a straight swap for the nova column... WRONG!!!!! very very wrong.
On a road car yes you can swap them straight over but not on mine, the motor assembly was fouling on the dash bar big time. I knew i was going to have to drill out the spot welds on the column mount anyway cuz the position on the seats relative to the wheel was all wrong. So i ended up hacking up the column mount and fabricating some bits to have it all go back together with the mount welded to the dashbar/chassis with everything repositioned such that the wheel sits a few inches more to the right and about 6 inches lower. So here's how it went:

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0859.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0859.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0858.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0858.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0861.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0861.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0863.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0863.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0866.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0866.jpg.html)

Position is perfect:
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0868.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0868.jpg.html)

Test sample for the cage done:
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0869.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0869.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0871.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0871.jpg.html)

Welded up boot lock hole
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0874.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0874.jpg.html)

So thats it for now. Bidding on some mk3 golf calipers on ebay to see if that solves my rear brake issues. I heard from someone else who did the conversion that yes the wheels do sit a bit closer to chassis with the golf discs on and he used 6mm wheel spacers to get them back in the right place, simples.

Had a really hard time getting the front hub bearings out. Looks like im going to have to get a garage to press in the new bearings for me. Once thats done ill have everyting i need to get the front suspension rolling. Plan is to look at spraying the exterior once its rolling.

May have an issue with the fact that ive drilled the rear strut brace to fit harness bolts. Need to talk to a scrutineer about it, if he says its a no no then ill be cutting them off and welding up the holes.

Thats it for now.

[tomfromdelmonte]

Weld test sample sent off yesterday so fingers crossed!!!

BARS test plus a half day rallying this Friday in Wales... should be good fun

[tomfromdelmonte]

Weld sample has been approved. All i need to do is send off pictures of the cage with a disclaimer form and i should then have a certificate for the cage. Ive found a scrutineer who can logbook the car for me when it is complete. Things are looking pretty good. all i need to do is knuckle down and get the damn thing finished so i can logbook it and get out on a rally stage.

BARS test tomorrow and a half day of rallying at the Higgins rally school. Dropping in to Harry Hockleys on the way back and then over to Birmingham to collect some parts. Lets hope i pass the test (fingers crossed and all that).

[Benn]

Lovely welding on the cage.

[RallyMarshal]

Not sure if this will appear as Ive tried to post on this thread several times - Im not sure if it didnt appear because I was trying to quote a photo of your engine bay.

As it stands, the engine bay will not pass MSA logbooking as you have cut the bulkhead away.

You must either remove and plate over the blower/heater hole OR create a new bulkhead around the blower/heater such that there is a solid partition between the engine bay and the passenger compartment.

Its to stop the passage of liquids (ie fuel or oil) and flame. At the moment theres nothing to stop an engine fire / fluids from coming straight into the passenger area through the blower.

Paul..

[RallyMarshal]

Aha - it appeared!!

I guess I cant post or quote photos until I have a decent post count?

Also, dont forget double throttle return strings on carbs (in addition to the ones on the linkage), no fuel pipe joins inside the car (apart from in the fuel pump box obviously), fully sealed bulkhead around the linkages and holes taped up with aluminium tape. Couple of other things, make sure you have correct 4mm mudflaps no more than 80mm from floor when car unladen and 40mm wider than tyre plus cut off switch and extinguisher pull can be accessed by driver and codriver when belted in as well. Oh and codrivers horn too...

Paul..

[tomfromdelmonte]

Thanks for the advice Paul. This is the first post ive seen from you (but hopefully not the last!). I will have to fabricate something out of sheet metal as im told i will need the blower to stop the window misting up.

[RallyMarshal]

Oh and Id also like to say.. Extremely well done with the car so far.

I run a 1400cc 8v Astra Mk2 - the 8v lump is known as "Old Faithful" as we keep refitting it after other engines have failed. Its a std bottom end with ARPs, 1300 big valve head, solid lifters, Kent AST17 cam, twin 40s etc. Its around 106bhp at the wheels but its enough to have won our class at Jim Clark 2012, Rockingham 2012, Rally Barbados 2013 and we just won the trophy rally at Rockingham on the Sunday when we blew the newly fitted 2000cc on Saturday, fitted "Old Faithful" in 2.5 hrs on Saturday night and went back down to do the Trophy Rally on the Sunday..

1 - Build the car safely and compliantly. Remember that a new build car with a 1400cc has to weigh 840kg, 1600cc has to weigh 920kg and a 2000cc needs to weigh 1000kg. Your doing a good job on this :-)
2 - Get the handling sorted (dont go too stiff - I run 8" 275lb springs front and Eibach Sport rear pigtail springs)
3 - Fit decent brakes (I run a bias pedal box, Astra GTE 16v 256mm fronts with Mintex F4R pads and Astra 16v rears with the cheapest pads I can find to reduce the rear braking)
4 - Fit a reliable engine and box and dont worry too much about the power aspects of it. A decent ratio box (ie a Quaife F20 SCCR with 4.8 which is what I run) is worth it.
5 - Get used to it - seat-time on events is THE most critical factor to you being competitive. Learn to carry speed through the corners, brake effectively etc
6 - Then fit something with more power....

Paul..

[RallyMarshal]

I used to rally a Nova back in the early 2000s. Actually bought the shell from Colin Smith on here (Novarally) as it was a hillclimb shell originally. Killed it in 2005 after a coming together with another car on a single venue event and a reshell into a Corsa shell didnt end up happening and then moved onto Mk2 Astras.

This was my Nova - http://www.teamrallymarshal.co.uk/car.asp

Paul..

[RallyMarshal]

I used to rally a Nova back in the early 2000s. Actually bought the shell from Colin Smith on here (Novarally) as it was a hillclimb shell originally. Killed it in 2005 after a coming together with another car on a single venue event and a reshell into a Corsa shell didnt end up happening and then moved onto Mk2 Astras.

This was my Nova - www.teamrallymarshal.co.uk/car.asp

Paul..

[RallyMarshal]

I dont know if this link will work, but this is a long thread on the Astra MK2 OC forum about mine..

www.astra-mk2.com/forum/showthread.php?28736-Mk2-Astra-Rallycar-from-bare-shell-upwards

Paul..

[tomfromdelmonte]

Paul, id love to fit a quaife gearbox but the budget doesnt stretch to it. About the closest thing ive got is a white nylon quaife style gear knob :). Ive got the bits to build a 'poor mans rally gearbox'. F13 close ratio cluster with a 4.2 FD and a quaife LSD, not bad for £400 all in which is mostly the cost of the 2nd hand diff. Obviously i havent tried it yet so i dont know how good it will be but will probably be fine while im still a novice. I have Astra brakes for the front and golf things for the back.

As regards the engine.. like you say its pointless trying to go for big power at the moment. All im doing is bolting on the twin 45s ive got for it and putting some arp bolts and cams in (theyre not wild, so ive been told). Should make a fair chunk of power though (140 bhp perhaps?), hopefully thats not too much.

[tomfromdelmonte]

Just had a look at the Nova.. that looks awesome!!!! how did the barbados rally go? the website doesnt have any info since you left for the rally!!! 10 years ago!!!

Just out of interest you said the engine let go at MIRA and was found to be damaged. Do you remember what the damage was? what was the new engine that i put in it for the rally?

[RallyMarshal]

I used to run an F13CR (Nova GTE) box with 4.18CWP in the Nova. I did however run a plated ZF diff - would be the first upgrade over an ATB for me but the box will be fine. On a 4.2CWP Id look at running 13" or 14" wheels rather than 15" as it will help with the overall gearing as well. I only went 15" on the Astra after I went to a 4.8CWP.

I have an old Quaife F10 SCCR with damaged 2nd gear in the garage which may be for same at some point.

I went for the Astra GTE brakes as its easy on an Astra rear beam plus the separate handbrake on cables makes it easy for MOT and scrutineering. How are you doing the handbrake part on yours? You need a cable handbrake to be legal - a locking pin on the hydraulic handbrake shouldnt pass an MOT and wont pass scrutineering if picked up.

The engine at MIRA just let go - we think the valve failed and the valve head came off but dont know if that was because the piston hit it first due to a hydraulic lifter issue or a spring failing or similar.

Barbados 2003 is on Youtube at www.youtube.com/watch?v=Ugpb-PvtAbg

My "rally channel" with incar including Barbados 2011 and Barbados 2013 is on there plus most other events too. Its at www.youtube.com/rallymarshal

Paul..

[gary_126]

Some great advice there, safe, reliable, simple and enjoy it! Too many chase tech spec and loose sight of what its all about, having great fun! :D

[tomfromdelmonte]

Gary, i couldnt agree more.

Passed my BARS test today and drove a rally car for the first time ever... face aches from grinning too much lol.

[Slippy]

Gary, i couldnt agree more.

Passed my BARS test today and drove a rally car for the first time ever... face aches from grinning too much lol.

:thumb:

[RallyMarshal]

This came up on another forum...

www.britishrally.co.uk/classifieds_view.php?id=14701

Paul..

[tomfromdelmonte]

Awesome, thanks Paul. Ive sent him a PM.

[RallyMarshal]

Whilst I hate to be the bearer of potentially more bad news, came across this from the MSA blue book...

48.1.4.
With the exception of cars accepted under 46.3
(see 46.3.7), and cars with modifications conforming to
their homologation papers (46.2) floor pans, bulkheads
and transmission tunnels may not be modified other
than by localised alteration to accommodate the fitting
of an alternative engine and/or gearbox and/or
differential and/or axle, seats and exhaust.

You may find that replacing the tunnel in the manner you have will contravene the technical regs - its debatable whether it would be classed as a transmission tunnel or whether you could argue its an exhaust tunnel and the rule doesnt apply..

How are you progressing with it now? Any updates?

Paul..

[tomfromdelmonte]

Interesting point. The purpose of replacing the tunnel was to provide a stronger mounting point for the seat rails so hopefully that would satisfy the condition of 'accomodate the fitting of...seats'.

Have been super busy on the car last few days (much better than lounging around in a food-induced coma) and am now the proud owner of a rolling chassis which is a major step forward. also fitted the hockley quickrack, poly rack bushes. Removed the ****e flo-flex rear bushes and replaced with rally design items. Got some mk3 golf rear calipers which have solved my rear brake issues. I'll let the pics do the talking.

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0879.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0879.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0880.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0880.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0891.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0891.jpg.html)


http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0892.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0892.jpg.html)

old vs new
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0918.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0918.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0917.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0917.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0920.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0920.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0921.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0921.jpg.html)

And this is how i roll!!! (literally)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0915.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0915.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0914.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0914.jpg.html)

Pretty happy with todays efforts. Next jobs are some fabrication of the A and B pillar gussets and make a bulkhead to go round the blower motor. Also need to plumb in the fire extinguisher and fit the exterior pull cords for that and the battery cut off. Probably be a good time to make another to-do list.

[Slippy]

Well done mate :thumb:

[tomfromdelmonte]

pics from today. didnt do much except tidy the garage and potter about...

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0923.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0923.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0924.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0924.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0925.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0925.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0926.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0926.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0927.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0927.jpg.html)

[tomfromdelmonte]

Set about making some gussets. Why the f*** i didnt do this before there was paint on the shell i dont know.

Numpty!

Did a bit of sanding and filling in preparation for the paint that will be going on tomorrow or the day after.

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0949.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0949.jpg.html)
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0950.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0950.jpg.html)
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0951.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0951.jpg.html)
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0952.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0952.jpg.html)
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0953.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0953.jpg.html)

[philip]

Fair play. Ace seeing bare shell builds. Ive got a few similar in new year once moved to a larger unit. Where did you get swage's from for the gussets? Cant seem to find a decent set anywhere.

[Benn]

Nice welding on the guests.

[dgbnova#1]

Fair play. Ace seeing bare shell builds. Ive got a few similar in new year once moved to a larger unit. Where did you get swage's from for the gussets? Cant seem to find a decent set anywhere.

There was some on eBay full sets and individual ones also

[Balley]

Very nice work.

[tomfromdelmonte]

Yep they are just ebay jobbies. Takes some proper elbow grease to tighten them up enough though. I think youre supposed to use a press.

[philip]

Ill have a nose. Ive got a press if need be :) cheers

[8valve-craig]

Yep they are just ebay jobbies. Takes some proper elbow grease to tighten them up enough though. I think youre supposed to use a press.

Can you not use a gun? Or would that be a bit overkill?

I had a guy make mine for me, Worked out around £6 a corner delivered which I was very pleased with.

[tomfromdelmonte]

Well ...

Happy New Year to all, and here's to 2014 being the year of the rally nova (and first of many!)

Did something today ive been dying to do for ages, turned the car round so it faces out of the garage. Makes sense because im mostly rubbing down the rear quarters at the moment and prepping for some paint. The color i have is Vauxhall Glacier White which appears to be much closer to grey than the bright white that the interior is (Ford Diamond White).

I also fabricated a second bracket for the EPAS column that sits further down and supports the motor assembly. This was a real ball ache but im glad its out of the way. Didnt get any pics of it but i will tomorrow. Yesterday i welded on some 'tags' to tie a few parts of the cage to the chassis like the B-pillar, dash bar and also put one on to support the roof better. I suppose eventually i'll roll the car and have to spend time pushing all the dents out of the roof.

So here we are...

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0959.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0959.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0955.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0955.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_0962.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_0962.jpg.html)

[tomfromdelmonte]

Well ive resprayed the shell now... and it look... passable. Havent done the wings though as im doing those separately.

Way too much overspray on the roof and it needs flatting down and redoing. Sprayed the tailgate this morning and that was a complete fcuking disaster. Its safe to say i hate painting. Really want to be done with this ****e do i can get on with the real work like doing the wiring and building up the engine/box. Hopefully the decals will cover up most of the crap paintwork.

Started to look at doing the fire extinguisher pipework. Ive mounted the bottle in the wrong place and wasnt really thinking when i did it.

Anyway. Pics:
http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_1008.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_1008.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_1007.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_1007.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_1005.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_1005.jpg.html)

Will be much happier when the polycarb windows are in and the doors are on. I bet that takes about a month!

[mk1nova_rich]

Coming along nicely mate, congrats on passing the BARS test :)

[kbf71]

Looks good from here Tom! Where are you planning to move the extinguisher to?

[Connor]

Oh and Id also like to say.. Extremely well done with the car so far.

I run a 1400cc 8v Astra Mk2 - the 8v lump is known as "Old Faithful" as we keep refitting it after other engines have failed. Its a std bottom end with ARPs, 1300 big valve head, solid lifters, Kent AST17 cam, twin 40s etc. Its around 106bhp at the wheels but its enough to have won our class at Jim Clark 2012, Rockingham 2012, Rally Barbados 2013 and we just won the trophy rally at Rockingham on the Sunday when we blew the newly fitted 2000cc on Saturday, fitted "Old Faithful" in 2.5 hrs on Saturday night and went back down to do the Trophy Rally on the Sunday..


I bumped into you lot with the astra at rockingham, and i spoke to you sunday about you going back to fit your engine failure and you going back saturday night to refit the old engine again lol. Fair play to you lads :thumb: was a good weekend :)
I was servicing for this bunch
https://scontent-a-lhr.xx.fbcdn.net/hphotos-prn2/1463344_10151881934769926_1207216188_n.jpg

[Connor]

Tom i don't get chance to get on here very often but this is one of my favourite builds i have seen for a while, lovely executed so far and so very nice fabrication so far, loving the cage, we have just gone for the same version i believe in the new nova build i'm helping out with. The small block XE engines are perfect for these nova rally cars, and the 14xe i help out with is often winning best seeded in the rallys, shows many of the big boys how to do it :P
Hope to see you out on some stages in the near future :thumb:

[tomfromdelmonte]

Cheers Connor, you've definintely provided my motivation for today.

Kenny i just need to turn it round 180 degrees as with the angle of the discharge at the moment i cant get the pull cord and tubing in there. Ill post some pics this evening after ive sorted it out.

[Connor]

Cheers Connor, you've definintely provided my motivation for today.

Kenny i just need to turn it round 180 degrees as with the angle of the discharge at the moment i cant get the pull cord and tubing in there. Ill post some pics this evening after ive sorted it out.

No worries, you've certainly cracked on and progressed considerably in a short period of time, good work!

As for the fire extinguisher i think the position is decent and agreed on switching it round 180 degrees, are you planning on plumbing it into the engine bay i presume. Just please test it with a dummy extinguisher or similar to see if the extinguisher gives out enough force to actually extinguish a fire, very recently seen a rally car burn itself to pieces due to the plumbed in extinguisher failing when the oil feed pipe to the turbo split causing an engine fire. Then due to idiots not being upto knowledge in fire safety, bystanders caused the fire to be 100% causing excessive damage to the car and also people trying to extinguish the fire including the driver and co-driver. People underestimate the importance of a decent extinguisher system, and there's nothing worse than seeing someone's pride and joy burn to pieces and there's nothing you can do to stop it.

Looking forward to seeing progress :thumb:

[tomfromdelmonte]

It hadnt occured to me to test the extinguisher but now you say it , it does make perfect sense.

I ended up moving the extinguisher to behind the co-drivers seat. I had to weld some bolts rather drill through and use rivnuts as the fuel tank is directly below and sits flush with the chassis so not enough room even for a rivnut. Got the whole thing plumbed up except for the 2 nozzles that are supposed to discharge into the cockpit as ive run out of tubing. Also the kit came with a 12ft and a 6ft pull cord. The 6ft cord is useless and is not long enough for either the external run or the run from the dash to the cylinder #FAIL!!! bit annoyed about that.

I did a bit more fettling with the dash and got it too fit but ive cut out rather more than i would have liked to get it in. I may have to make some something to cover up the horrendous gap although its not that much of a big deal at the moment. Polycarb windows are ready to go in although thats a job im saving for next week. Starting to look pretty cool although the loom is starting to feel like a fairly daunting task.

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_1012.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_1012.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_1018.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_1018.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_1023.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_1023.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_1024.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_1024.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_1027.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_1027.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_1016.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_1016.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_1017.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_1017.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_1020.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_1020.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_1021.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_1021.jpg.html)

http://i1236.photobucket.com/albums/ff451/tomfromdelmonte/SAM_1024.jpg (http://s1236.photobucket.com/user/tomfromdelmonte/media/SAM_1024.jpg.html)

So thats it until next week. Ill be making a start on the wiring. Ive ordered a race battery from ebay. At least its something i can plan and draw out while i away.

[tomfromdelmonte]

Im having the rally decals made up by a company in bristol - http://www.briz-graphics.co.uk/

Their prices are excellent and the service i have had from them so far has been very good. I think the company is run by a competitor and his wife.

Anyway, ive been asked if i can provide the measurements/dimensions of the bonnet but im in London all week and dont have access to my nova so i was wondering if any of you fine chaps on here could provide this info for me?

cheers muchly

[8valve-craig]

Front edge (headlight's) 1230mm,
Length (along wing) 880mm,
Rear edge (scuttle) 1270mm

[tomfromdelmonte]

Cheers Craig!

[tomfromdelmonte]

Ive bought an odyssey battery and this weekend will be making a start on the loom. TO be honesy im not even sure where to start. Does anyone have any suggestions or experience here? i guess the first thing would be to sort out the wiring to the cutoff and make off the ends etc. Probably have to buy some cable and terminals.

I have a standard 1.0 L nova loom as a starting point. The engine is going to run twin 45s so no need to worry about ECU and i have an MBE system to run the ignition.

[RallyMarshal]

My suggestion for the wiring with such a basic loom to start off with..

If the loom is in good condition and isnt cut about, remove the simple parts (ie stereo, speaker cabling, aerial) and anything else easy to remove (electric windows loom maybe) and dont really touch anything else.

Unwrap the main battery cable that goes from the battery to the fusebox in the standard loom. That will be the "output" from the master cutoff and will feed to the standard fusebox.
Add a new battery cable from the battery to the cutoff as the "input" to the cutoff.
Theres a secondary wire with an inline resistor that comes from the cutoff on the "output" side that goes to earth - this allows any current from the alternator to be consumed if the cutoff is used. Have a look at the wiring diagram for this.

Add a secondary feed from the cutoff to a separate relay / fuseboard and then keep each circuit as simple as possible with a fuse / relay / etc as needed and add any additional earths needed.

Use the original earths for std lights etc. Add an additional engine to chassis earth as well.

If your wiring in an ignition switch and start button, peel back the wires from the ignition barrel one by one and wire them into a decent amperage toggle switch for ignition and push switch for the start button.

Paul..