1992 Merit Plus - here we go again!

[kevw]

So, I've bought a new project.

http://i249.photobucket.com/albums/gg240/kev-w/1992MeritPlus/89f2c008-9268-49fb-9af3-bab10dd78a20_zps5c8320d4.jpg

This was a bit of an impulse buy, I've been getting the urge to do another project for a while but it comes and goes, I guess that urge finally got the better of me.

Bought this off Joshy (http://www.pngclub.com/forum/member.php?178556-joshy) on here for a good price, downside was that it was 280 miles each way to go and get it. I dragged novaload_nick (http://www.pngclub.com/forum/member.php?13393-Novaload_Nick) with me on Sunday, setting off at 08:00 and not getting back until about 21:00 I think it was. It was a long day but went pretty quick. A dodgy motorway services breakfast plus a box of 12 Krispy Kreme donuts got us through along with some "energy mints" that we tried. The mints were rubbish.

After a few incorrect turns because of the satnav freezing we got to where the car was. The next fun and games came when we were driving the Nova onto the trailer and it got stuck because it's pretty low. Had to reposition the trailer and do a bit of lifting lol

The shell will be a good base although after poking about a bit when I got home it has the usual rust hiding underneath seam sealer and the like. Despite that and at least one dent in every panel everything lines up as it should which is what I was looking for.

http://i249.photobucket.com/albums/gg240/kev-w/1992MeritPlus/IMG_20140526_135411_zpsaf77d3ca.jpg

I'm not going to go down the stripped out track car route with this one. First thing will be to get the bodywork all straight and painted and a tidy full interior. I will use it more if it has a full interior as the kids can come in it.

So, if I can get going on this it will soon be a tidy Merit Plus in red with black bumpers and a decent interior, hopefully I can find GSi stuff. I'll sell the wheels that are on it as I have some Cav Expression alloys that I'm going to try. The current front coilovers will stay for now and I have some lower rear springs to level it out, at some point I'll get some Gaz coilovers.

Long term I think I'm going to go for the smooth and subtle look, not sure what motor yet.

I have no idea when this will be on the road, it currently has no MOT and is SORN, it certainly won't be done as quick as the last project lol

:)

[millworm]

This was round the corner form me, seen it a couple times. My mates nova saloon has ended up in wales too :( . Good car for the money though, good luck with it

[Southie]

Should be a nice basic clean build then... and sloooow by the sounds of it lol
Nice to see you getting another one though ;)

[Novaload_Nick]

Looks rubbish.

[scott.parker]

Looks rubbish.

I'll second that, lol
Kev your nuts, why on earth would you inflict this upon your self again!.. lol

[kevw]

I have to admit, we were only 5 mins down the road and I was looking at it in the rear view mirror wondering what the hell I'm doing lol

[Novaload_Nick]

Lol it's not bad for the price you payed to be fair

[kevw]

@millworm loads of Novas have been brought into Wales and ended up being scrapped lol

[burgo]

Dunno where people get the enthusiasm

[kevw]

Burgo, it comes back when the kids get past a certain age lol

[Benn]

Looks like a good enough base, i like your plans too. An Interior is the way forward.

[kevw]

Just need to try and find a good GSi interior and not have to re-mortgage the house lol

[kevw]

Sort of made a start on this now.

Put different rear springs on, it's now level, before and after:
http://img.tapatalk.com/d/14/06/12/8e3yrehy.jpg

Took rear bumper off to see what it's like underneath, this made me very happy:
http://img.tapatalk.com/d/14/06/12/7uquvu9a.jpg

Took front bumper off to check out underneath, this made me sigh:
http://img.tapatalk.com/d/14/06/12/ebyheja2.jpg
http://img.tapatalk.com/d/14/06/12/2ymyde7a.jpg
http://img.tapatalk.com/d/14/06/12/ere2u4eb.jpg

Need to strip it a bit more before deciding on a new front panel or repairing.

Checked out underneath the passenger side wing and all looks OK:
http://img.tapatalk.com/d/14/06/12/6yjy7uty.jpg

It got dark so I packed up:
http://img.tapatalk.com/d/14/06/12/udarytuz.jpg

I was thinking of running the 1.2 this year (LOL) and just getting the car looking good. If I end up doing the front panel I might as well get the engine out and sort all the bay out, if I do that I may as well put something else back in.

Decisions.

[dgbnova#1]

Is the cross member gone or just the valance as can just fit that was one at Pvs as well

[Kev Turbo]

Front panel much easier to change than the back panel so good result.

What's your plans for it?

[kevw]

Is the cross member gone or just the valance as can just fit that was one at Pvs as well

Not checked cross member yet. I saw that one at PV, said to Nick it might be worth getting in stock. Wish I knew then what I know now!


Front panel much easier to change than the back panel so good result.

What's your plans for it?
Plans at the mo are:

Straighten it up
GSi front bumper - won one on eBay only to be messed about, still hunting
Need a mint MK2 rear
Fresh paint in original red, bumpers either flat black or metallic black
Big brakes - on the way to me
GSi interior - still on the hunt. May possibly go for some reclining buckets and get the rear bench re-trimmed to match
Got some Expression 15's that will be going black with new tyres
Get rid of the big steering wheel!


After that I'll get some Gaz coilovers and do something with the motor.

Something along those lines lol

[jimbob-mcgrew]

I was looking at it in the rear view mirror wondering what the hell I'm doing lol

been there a few times, lol

looks like a good shell tho, just a few patches needed on the front :thumb:

black expressions sounds interesting, get some pics of those :)

[kevw]

Here they are at the mo ;)

http://img.tapatalk.com/d/14/06/12/4e4ava8e.jpg

[kevw]

looks like a good shell tho

I think it's worth saving it.

[jimbob-mcgrew]

there 15 x 6 arent they ?

can squeeze 288 v6 brakes under them

[kevw]

Yea 6 wide. I'm just putting 256 under for now. I might not even like the wheels on yet lol

[kevw]

Quick update. Nothing of much interest really. Started stripping the car down last night.

Will get the engine out next and then be starting to sort the bodywork out. When I start pulling the seam sealer off there will definitely be rust to sort out.

The rear arches have (bad) repairs so I need to get them back to metal before deciding what to do. Probably repair panels.

Thanks to novaload_nick for giving me a hand :)

http://img.tapatalk.com/d/14/08/16/a9une4um.jpg

http://img.tapatalk.com/d/14/08/16/eqa7usat.jpg

Oh. Picked up some R1 carbs and a 16XE Bogg Brothers manifold off dgbnova#1 and pick up the motor off Scott in a couple of weeks ;)

http://img.tapatalk.com/d/14/08/16/jyryzeju.jpg

[scott.parker]

Nice to see your getting it ready mate, them carbs with the stainless manifold will possibly give 150+!...

[kevw]

Nice to see your getting it ready mate, them carbs with the stainless manifold will possibly give 150+!...
Cheer's dude. Just doing a bit here and there when I can. Yea should be a cool little motor! Long way off though

[kevw]

Bought an engine crane, Machinemart had sent me a "VAT off" voucher and it ended on Monday so I went after work and picked one up.

http://img.tapatalk.com/d/14/08/21/su2y2a4u.jpg

Then borrowed the Zafira off the missus and went to get the 16XE motor off Scott.

I was concerned about leaks so put the engine on some damp proof membrane and hoped for the best. Luckily got away with it, she'd kill me if I got anything on the seats or damaged anything!

Had to take the engine crane apart to fit it all in but just enough room!

http://img.tapatalk.com/d/14/08/21/ezyme5e4.jpg

When I got back it only took 30 mins to rebuild the crane and get the engine out. No idea how I would have done this without the crane.

http://img.tapatalk.com/d/14/08/21/8emu4e2a.jpg

http://img.tapatalk.com/d/14/08/21/henuqy2e.jpg

This is where it'll sit for a while until I get round to sorting it out.

http://img.tapatalk.com/d/14/08/21/guraruze.jpg

Need to take off all the stuff that isn't required and make a nice tidy loom. I was going to run it on the injection for a bit but might just go straight on the carbs so will need the extra bits required for that.

[scott.parker]

Glad it went well the other end dude, what other stuff do you need to run the car setup?
You can definitely dump the power steering pump, there some weight gone, and ditch that exhaust manifold.

[Southie]

Should be good when done, the only downfall on these engines is oil stem seals. Are you thinking of a engine strip down Kev?

[scott.parker]

No guarantee.... But I would like to think it's still all OK, as it had been sat a while, but ran brilliantly..

[Southie]

Scott after I had 4 different versions of these style engines I don't trust them for oil stems, also the cam timing pulleys come to think of it as one of mine failed on the timing and well...

http://i345.photobucket.com/albums/p379/SOUTHIE01/MINE/valvemeltdown.jpg (http://s345.photobucket.com/user/SOUTHIE01/media/MINE/valvemeltdown.jpg.html)

http://i345.photobucket.com/albums/p379/SOUTHIE01/MINE/pistonmeltdown.jpg (http://s345.photobucket.com/user/SOUTHIE01/media/MINE/pistonmeltdown.jpg.html)

[kevw]

Glad it went well the other end dude, what other stuff do you need to run the car setup?
You can definitely dump the power steering pump, there some weight gone, and ditch that exhaust manifold.

Thanks for your help mate. I'm not sure which way to go with it, distributor or megajolt etc


Should be good when done, the only downfall on these engines is oil stem seals. Are you thinking of a engine strip down Kev?

Not sure yet. I'll get rid of all the unneeded bits and get it on Nicks engine stand. Probably paint it up etc. Might be worth doing the seals then?


mine failed

Do one Dave you're scaring me lol

[scott.parker]

Iirc David weren't your engines c16? Think the X16 is stronger. As I say I don't think there will be any issues, but it might make life easier to drop it in on injection for now to start it up..

[johnd]

Very nice kev would love a set of carbs for my x16xe

[Southie]

Not scary, on my last one a C16xe I got a full rebuild using all gm parts... That came to £900... That was scary :(

[Southie]

Scott my first 3 yes 3 were X16xe's, only the last one was a C16xe that I had fully rebuilt due to the head gasket failing lol

Kev you'll hate me for saying this but unless it's been well looked after and a low mileage example then I think they're overrated unless rebuilt... My opinion though after years of spending on them!!!

[scott.parker]

How does 75.000 odd sound? Low enough? lol

[Southie]

How does 75.000 odd sound? Low enough? lol
Plenty of oil changes and decent services then... maybe lol

[kevw]

I might change my plans and fit pedals instead lol

http://www.gardenlines.co.uk/Assets/Berg%20Ferrari%20FXX%20Exclsuive%20BF%20Go%20Kart% 202.jpg

[Southie]

Nice rims lol

[kevw]

I was reading a thread about the stem seals issue and the general consensus was that if you're not bothered about a bit of smoke then don't go to any effort to replace them.

I'll maybe go for some different cams and headwork at some point so I guess that will be the time to do them :)

[scott.parker]

As I say Kev, I'd be tempted to drop it in ASAP and get it fired up to get the engine moving again, stop the seals hardening, not that I imagine they are now.

[kevw]

It won't happen that quick. Once the 1200 is out I need to get the bay all sorted and painted before the motor can go in. It'll be alright ;)

[kevw]

Spent a bit of time on the car today. Not touched it for weeks.

First thing was to have a look at the arches so I know what panels to order. Started on the drivers side:

http://tapatalk.imageshack.com/v2/14/09/28/c37f151a19b862b3849954422f660015.jpg

http://tapatalk.imageshack.com/v2/14/09/28/558fbdcdbfdd68584fdb35b9a0ee4b5b.jpg

That'll be inner and outer repair panels then. Didn't bother looking at the other side, I'll just order panels for both sides, I can't imagine the other one being good when I start picking.

http://tapatalk.imageshack.com/v2/14/09/28/d16016d3b0f6bd8e05a0bcb0cb06d981.jpg

It's had a repair panel there. That'll be all chopped away once I get started with the new panels.

Decided to get the engine onto the stand so stripped the gearbox off.

http://tapatalk.imageshack.com/v2/14/09/28/f282730fa7391a3a0ec642926cdd7135.jpg

http://tapatalk.imageshack.com/v2/14/09/28/f27d6eb03db82fee1add14b75c9ae60b.jpg

Next I'll strip all the injection off, give it all a big clean and get the carbs fitted :)

I now know that I need inner and outer arch repair panels and a front lower panel. Everything else is solid and straight. I'm quite happy with that.

[scott.parker]

Nice to see some progress, do me favour, smash **** out the power steering pump once it's off, what **** that made getter the engine out, dirty horid fluid lol

[dgbnova#1]

Your gona need to find a non porwer steering tensioner and bracket and pully for it when you ditch the Corsa mount just had to do it on one here
bit of progress always good

[kevw]

Nice to see some progress, do me favour, smash **** out the power steering pump once it's off, what **** that made getter the engine out, dirty horid fluid lol

Yea it was good to get some time in the unit! Not been there for weeks apart from to check on it. I've ordered the panels now so I can get cracking no it. There was still quite a lot of coolant hiding in there as well lol


Your gona need to find a non porwer steering tensioner and bracket and pully for it when you ditch the Corsa mount just had to do it on one here
bit of progress always good

I was thinking of making/finding a bracket to adjust the alternator so I don't need a tensioner...

[dgbnova#1]

Yes was my plan to do the same but the 1.4 I have had the required bracket tensioner and belt it was a no brainer for me took 10 mins and the motor was swinging already so a pain to piss about then but it looked simple enough to setup a bracket and with your motor out already it makes it far easyer

[kevw]

Any ideas what belt I can use?

[dgbnova#1]

I never even got close was about to start when Chrisd reminded me to check the 1.4 so just abandoned it my plan was to make bracket then on it's slacker setting measure it with string and get the closest belts to that size and just try them all

[kevw]

Yea that was pretty much what I was thinking, I'll have a Google about first and see if I can find anything.

[scott.parker]

Iirc I've got a Corsa 1400 8v alternator setup in the shed I got for this.. Think there a single v pully with trigger Teath and a sensor, flat fly wheel, and an f13 box lol
Best dig it all out and sell it..

[kevw]

Let me know Scott

[kevw]

Got a couple of days off work so spent a few hours at the unit today.

Got all this mud:

http://tapatalk.imageshack.com/v2/14/10/07/037c00da6cc423ff17efa07368fa44e4.jpg

Out of here:

http://tapatalk.imageshack.com/v2/14/10/07/8c4d662ceabac0096e23d89d01d46e09.jpg

Chopped a bit more off the outer arch:

http://tapatalk.imageshack.com/v2/14/10/07/f79f4e5ba3d4d6507fc23cc1b2777709.jpg

It'd had this patch put in but hadn't been welded to anything! Tonnes of seam sealer holding it in! The sealer was also creating a water trap, I've always made sure the water can run away when I seal stuff up.

http://tapatalk.imageshack.com/v2/14/10/07/eb144a7511374dbd725574a5b774e55b.jpg

Messed about chopping the outer repair panel down and then cut away the rust from the inner arch.

http://tapatalk.imageshack.com/v2/14/10/07/c39997b2de55e3fc8d5082a7be9247ea.jpg

Pushed the repair panel into the arch to have a look. Probably going to trim the panel to the size of the hole and fit it flush rather than with a lip:

http://tapatalk.imageshack.com/v2/14/10/07/572e25d227c0429e5d30a0c3f68dd9a8.jpg

[kevw]

My MIG keeps jamming. All I managed to do today was fit the inner arch repair panel. I hoped I would have had the outer one welded on too:

http://tapatalk.imageshack.com/v2/14/10/08/4e771e7c2d07367487a07779f7b01b34.jpg

[Rickyb]

Ive just read this from the start, looks a mint project keep up the good work.
Rick

[kevw]

Ive just read this from the start, looks a mint project keep up the good work.
Rick
Cheers mate, lots to do but it should be a nice solid, straight and clean car when done :)

[Iain]

Instead of butt welding the repair panel you could look at getting a joggler tool. Nice work going to be a good repair when done

[kevw]

Instead of butt welding the repair panel you could look at getting a joggler tool. Nice work going to be a good repair when done
Just had a look at joggling tools. Seem to be about £45. Might be worth getting one. Good call.

[kevw]

Still not got a joggling tool. Need to order one.

Found that the rot or even the poor repair behind the fuel filler had lead to rot inside the sill:
http://tapatalk.imageshack.com/v2/14/10/26/6415aa37f156e98ad4b00d55bcba0008.jpg

This was after picking but before cutting as above:
http://tapatalk.imageshack.com/v2/14/10/26/862b4c4ad5d2e9f6a0d55f2bb91b09ce.jpg

Checking clearance of the arch, I've folded the lip and will fold the outer lip too so there's plenty of room:

http://tapatalk.imageshack.com/v2/14/10/26/296dca912d0cfb35f4cdd3a644c643ba.jpg

[kevw]

Knocked up a patch before leaving for the day:

http://tapatalk.imageshack.com/v2/14/10/26/55c3e1a6d7d5a1351ff599bf5d5fb043.jpg

[Benn]

Very minty looking wheels.... Good work on the de-rusting.

[scott.parker]

Nice progress mate, shame you found more rot, but best to deal with it now!..

[dgbnova#1]

Always a can of worms when you get started lol

[kevw]

Very minty looking wheels.... Good work on the de-rusting.

Yea I like them, not sure what it's going to look like in reality though once I get tyres on etc. Plan is to do them black with a silver rim but not sure yet. Might just keep them silver for now. Got a lot of work to do and want it driving early next year!


Nice progress mate, shame you found more rot, but best to deal with it now!..

I'm hoping the other side isn't as bad. I don't think it is but haven't really looked yet lol I couldn't just cover it up and pretend it's not there so unfortunately had to cut that big flap out to get in and patch it up. Needs must.


Always a can of worms when you get started lol

Yea man, you've had your fair share of worms in your workshop by the looks of it lol

[Southie]

Looks like your getting stuck into the rot now, nothing worse than chasing decent metal as it's sole destroying thinking " Ahhh nearly there.... Feck more bloody rust".

Keep going your breaking it's back now ;)