Nicks x18xe1 build (PBpatched)

[totalnova]

Well this is my second nova, my first nova was a flame red 1.2 and it was m first car and it was a rust bucket.

Over the Autumn and winter i will be rebuilding it from the ground up and replacing any panels that need doing and patching any small bits that need doing.

I will be eventually once the shell is ready be putting in a small block 1.8 z18xe and maybe next year i will be supercharging it but i will see how that goes as we all no plans change.

Anyway pics of today's efforts

http://i5.photobucket.com/albums/y155/totalnova/nova4-1.jpg~original


http://i5.photobucket.com/albums/y155/totalnova/nova5-1.jpg~original


http://i5.photobucket.com/albums/y155/totalnova/nova6.jpg~original


some rust that needs sorting.....

http://i5.photobucket.com/albums/y155/totalnova/nova1-1.jpg~original


battery tray has had a patch before but looks in good condition

http://i5.photobucket.com/albums/y155/totalnova/nova3-1.jpg~original

Well thats it for today, more stripping next week.

[Benn]

A 1.8 supercharged Nova would be a lot of fun. Doesn't look a bad start either.

[totalnova]

It looks very clean but it does need work.

It needs two new doors a new front wing and both rear wings need sorting as well, one of the rear wings has been done but not to a very high standard, so I'll be doing it again.

But underneath is very clean and the rear legs are very clean. So in reality it's a pretty solid shell.

[Benn]

Sounds good. Will make great base.

[totalnova]

well spent a quick half an hour in the garage this afternoon just to see how far this bit of rust went

http://i5.photobucket.com/albums/y155/totalnova/nova1-1.jpg~original


so got the grinder out and started cutting and thankfully its not to deep

http://i5.photobucket.com/albums/y155/totalnova/Mobile%20Uploads/IMAG0605.jpg~original

http://i5.photobucket.com/albums/y155/totalnova/Mobile%20Uploads/IMAG0607.jpg~original

Now i haven't finished cutting yet but most of the rot has been cut away.

i know this is a common place for a nova to rot so i was hoping for some help of the best way to tackle this as its three pieces of metal joining together and its not as simple as cut out and weld in new bit.

Cheers Nick

[Benn]

Gotta say id cut it back father than that, get rid of the rust back to clean metal, id put one bit on the leg flat, then a shapped one from the inner wing bit.

[totalnova]

Yeah I will cut back more just couldn't get to where I wanted to cut with the angle grinder so I had to go and get some cutting discs for the dremel, so I'll have another go tomorrow. Thanks for the advice on the repair.

[totalnova]

Well its been a very busy last few months with work, plus me and the wife had our delayed honeymoon so not much has been done to the car but i have been buying up bits and pieces

one of the bits was this

http://i5.photobucket.com/albums/y155/totalnova/Mobile%20Uploads/IMAG1151.jpg~original (http://s5.photobucket.com/user/totalnova/media/Mobile%20Uploads/IMAG1151.jpg.html)

Ignore the weeds please ;)

and i need the lower valance to replace this

http://i5.photobucket.com/albums/y155/totalnova/Mobile%20Uploads/IMAG1153.jpg~original (http://s5.photobucket.com/user/totalnova/media/Mobile%20Uploads/IMAG1153.jpg.html)

I have started to cut it out but gave up after my spot weld drill bits was all blunt, so i need to buy more.

Also ive cut out the rust from the bay and made new bits to go in, just waiting for my welding gas to be delivered so i can crack on with that.
hopefully ill have a major update next time

[Kev Turbo]

Look forward to update son the Z18 install. I am suprised this conversion is not seen more often as it is a very capable engine iwth the right bits bolted to it and makes for an easy conversion with the small block!
Good Luck

[totalnova]

Look forward to update son the Z18 install. I am suprised this conversion is not seen more often as it is a very capable engine iwth the right bits bolted to it and makes for an easy conversion with the small block!Good LuckI really do agree, it's such a good engine with so much potential, in years to come I think it will become very popular.

[Kev Turbo]

You can get a brand new motor reconditioned for around £1k as well! I am seriously considering one for my next conversion.

[dgbnova#1]

I find the lack of tuneing parts puts people off the 1.8 even the Astra forums don't have much as spares so it's buy new most of the time this is why there less popular id say

good job so far

[Kev Turbo]

From my limited reading 180+ is easily achievable with uprated induction (TB;s / Carbs) and cams on a standard engine with ARP's. I think the cost of the TB's is generally off putting and people tend to go down the forced induction route for the instant power and future tune-ability.

I would be interested to see some weight figures on how much a small block z18 would save you in Kg's over going big block C20XE / LET.

[staggy_gsi]

Could you make a 1.8T using the z18 engine and a corsa vxr turbo setup? Or does the turbo manifold not match the z18 head? I think that would make a cracking engine.

Car looks like a decent base for the project mate, Il be keeping an eye on this one!

[Kev Turbo]

Can not advise on that one Staggy. There have been several 1.8 T conversions carried out over in Corsa C world.

Google will pull them up if your are interested.

[totalnova]

This is something I've looked into and it will definitely help if I do go down the supercharger route, but I'm still not decided what direction to take with the engine.

[Rickyb]

Liking this, more updates needed.

[totalnova]

Liking this, more updates needed.

There will be more substantial updates soon I hope, its just work keeps getting in the way. I hope to have all the welding done by Christmas and then I'll start getting it ready for paint

[jimbob-mcgrew]

whats your plans for the throttle ? i dont know much about the fly-by's ... can you pinch a mk.4 astra pedal for it ?

any idea if theres much weight difference between the 16xe and the 18xe ?

[dgbnova#1]

It's a bigger motor slightly taller I think so must be a little heavyer

[_Jake]

Nice to see something different on here for once, should go well

[totalnova]

Spent an hour or so cutting out the lower front panel, not all done but gave up because its getting late

http://i5.photobucket.com/albums/y155/totalnova/IMAG1187.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1187.jpg.html)

Sorry for the crappy picture.

[totalnova]

Well spent a few hours on the car today, first i had to drag the car out so i could give the garage a good clean.

http://i5.photobucket.com/albums/y155/totalnova/Mobile%20Uploads/IMG-20141114-WA0001.jpg~original (http://s5.photobucket.com/user/totalnova/media/Mobile%20Uploads/IMG-20141114-WA0001.jpg.html)

once i was done cleaning i removed the radiator and came across this lovely sight.

http://i5.photobucket.com/albums/y155/totalnova/Mobile%20Uploads/IMAG1215.jpg~original (http://s5.photobucket.com/user/totalnova/media/Mobile%20Uploads/IMAG1215.jpg.html)

Now I knew there was some rust there but with the rad on it didnt look to bad, I thought i was only surface rust, I was wrong. for anyone who hasnt worked on this area before it is doubled skinned thankfully after peeling back the top layer the bottom layer is savable

http://i5.photobucket.com/albums/y155/totalnova/Mobile%20Uploads/IMAG1223.jpg~original (http://s5.photobucket.com/user/totalnova/media/Mobile%20Uploads/IMAG1223.jpg.html)

Still a bit more to trim on the side and then weld in a new piece, but i got bored and hungry so called it a day.

On a happier note I picked up my engine last week, I was going to use a z18xe but its more complicated then the x18xe1 to install and for the price I payed I couldn't turn it down, i also got the loom and ECU and transponer and key chip in the deal, just need an early f15 gearbox that has a cable speedo to bolt up to it now.

Well thats it for now, hopefully there will be some welding next update.
Cheers Nick

[totalnova]

Oh and if a Mod could rename this to Nicks X18XE1 Build. Cheers

[nova_stee]

Looks good iam about to do the same conversion on mine shortly but need the bay side of the loom

[dgbnova#1]

Does your x18 not need a speed sender or are you gona use the one from a nova with the cAble outlet at the top ?

[totalnova]

That's one part im not looking forward to. This is my first go at a convertion and rebuild and the wiring is the bit that scares me the most.

[dgbnova#1]

I'm ok on wireing things and even my x18 had me scratching a little tbh

[totalnova]

Does your x18 not need a speed sender or are you gona use the one from a nova with the cAble outlet at the top ?

The plan is to use an early gearbox that uses a cable speedo like the nova, i could even use an f13 if i wanted to.

[totalnova]

I'm ok on wireing things and even my x18 had me scratching a little tbh

have you got a build thread for the x18?

[nova_stee]

The wirings not hard, no harder than a x16xe

[dgbnova#1]

So I believe but time will tell looks a bit more involved to me

[nova_stee]

Just print the wiring diagram off auto data

[dgbnova#1]

Don't have that to do that

[Crossy]

http://www.allcorsa.co.uk/forums/showthread.php/x18xe1-engine-conversion-11880.html

Have a look at this mate. Might be of some help!

[dgbnova#1]

Mine is a little more involved as it's from a mk4 Astra has a different connection to the early vectra but similar IDea but a lot more wireing to do handy link though saved it for reference

[totalnova]

http://www.allcorsa.co.uk/forums/showthread.php/x18xe1-engine-conversion-11880.html

Have a look at this mate. Might be of some help!

yeah ive seen that before, but thanks for posting it.

[totalnova]

Well spent an hour on the car today after a few hours at work, managed to get some welding done on the inner wing.

you can see the hole one near side inner wing

http://i5.photobucket.com/albums/y155/totalnova/nova6.jpg~original (http://s5.photobucket.com/user/totalnova/media/nova6.jpg.html)

I had to shape three plates and put them together where the old metal had rusted.

http://i5.photobucket.com/albums/y155/totalnova/IMAG1248.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1248.jpg.html)

First two plates welded in

http://i5.photobucket.com/albums/y155/totalnova/IMAG1252.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1252.jpg.html)

All three in, i had to basically spot weld the whole thing in as you simply blow straight through if you try and continuously weld,

More next week, I want to have the whole bay painted by the end of the year, that's my mini target,
Cheers for looking, Nick

[totalnova]

could a Mod please change the title please to Nicks x18xe1 build

[Southie]

Title changed, nice looking project so far ;)

[totalnova]

Title changed, nice looking project so far ;)

Cheers cant wait to drive it, but on the other hand I dont want to rush it either. :d

[jimbob-mcgrew]

hey nick - whats the score with the vss on these ? .. do you just snip the original wire going to the hub sensor, and link it to a 6 pulse gearbox sensor ?

[totalnova]

Erm if your talking about the speed sensor on the gearbox I won't be using one, I'll be using an early gearbox that the Speedo cable on the nova will plug into. If that's not what you ment then I'm not sure sorry.

[jimbob-mcgrew]

between the cable and the box i mean.

like this :

http://i22.photobucket.com/albums/b338/Sammy_P1/IMG_1322.jpg~original

http://img.photobucket.com/albums/v297/rob_lee_1/DSC00982.jpg

a fair amount of people have done the conversion into various vauxhalls.

but theres next to no info regarding the ecu's speed signal, and im not quite sure how its done myself.
im just assuming it can be done this way, like the 1.4 and 1.6 engines, but im not entirely sure if it uses the same type of system.

without it wired in, the engine will probably stall when the car comes to a stop.

[tom reid]

This should be a decent wee motor when it's done, any thoughts on the final drive ratio?

[totalnova]

This should be a decent wee motor when it's done, any thoughts on the final drive ratio?

Im hoping to get an early f15 cr, I dont know the ratios off the top of my head but it should work well for what i need, plus im cetain with an early gearbox i wont need to use a speed sensor.

Hopefully ill have an update soon

[Southie]

You'll need the speed sensor due to the car needing a signal sending to know the speed, other wise when you come to a stop and dip the clutch these engines have a tendency to stall.

[totalnova]

You'll need the speed sensor due to the car needing a signal sending to know the speed, other wise when you come to a stop and dip the clutch these engines have a tendency to stall.

thanks for the advice, ill look into it, looks like anther item to add to the wanted list

[totalnova]

well there has been a few who have done the x16xe conversion someone must be sure what is needed???

[totalnova]

Well good news I've been doing some research and it turns out that because my car was a late 1.2 injection model it already has a vss that should be fine to use with the x18xe1

http://i5.photobucket.com/albums/y155/totalnova/IMAG1304.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1304.jpg.html)

Happy days, I hope.

[jimbob-mcgrew]

is it the AA, 6 pulse ?

i hope it works. when you planning on a test start ?

where did you find out by the way, i couldnt get any info

[totalnova]

Found a few bit and pieces on some forums like this

http://www.migweb.co.uk/forums/engines-transmission/199314-vehicle-speed-sensor-x16xe-nova.html#/forumsite/20932/topics/199314

[totalnova]

is it the AA, 6 pulse ?

i hope it works. when you planning on a test start ?

where did you find out by the way, i couldnt get any info

I'm a while away from a test start, I'm still preping the bay at the moment and I need to find a new f15cr gearbox.

[jimbob-mcgrew]

check this out mate. all the info you need :

http://www.corsasport.co.uk/board/viewthread.php?tid=458623&page=1

[totalnova]

Cheers mate, I really need to crack on with this, but work keeps getting in the way

[jimbob-mcgrew]

dont worry, im not trying to rush you lol

i know what you mean tho, were all too busy to dedicate the many hours necessary. especially at the moment, with the short days/lack of light, and the ice and snow on its way.

ive got a few things i wanna do to my car too, but unless its an emergency, im not gonna bother till spring time

[novarally]

I'm a while away from a test start, I'm still preping the bay at the moment and I need to find a new f15cr gearbox.

I've got an F15 here, out of a Corsa B SRi. Drop me an e-mail if any use to you.

[totalnova]

Only a small update, I started out the day with the intention of removing the underseal from the front wheel arches, about ten minutes in i found some tin worm hidden under the underseal, access wasn't to bad as it was also in the battery tray, lucky I caught it early.

http://i5.photobucket.com/albums/y155/totalnova/IMAG1358.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1358.jpg.html)

View from above

http://i5.photobucket.com/albums/y155/totalnova/IMAG1360.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1360.jpg.html)

Ignore the dodgy garage trainers

And all repaired

http://i5.photobucket.com/albums/y155/totalnova/IMAG1361.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1361.jpg.html)

The welding isn't perfect but its strong and will do, nothing the grinder wont sort.

I've done loads more that ill update later including two rust free doors i picked up

[totalnova]

Feeling really disheartened at the moment, found some rust and it might just be to far gone, I'll uploads some pictures in a few minutes.

[totalnova]

well i knew there was some rust in the scuttle area as i had seen this

http://i5.photobucket.com/albums/y155/totalnova/IMAG1369.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1369.jpg.html)

i then went inside and peeled back the carpet and found this

http://i5.photobucket.com/albums/y155/totalnova/IMAG1370.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1370.jpg.html)

Now im new to this whole restoration stuff and im learning as I go, so in peoples opinion is this repairable? its in such a hard location to get to, even thinking i might have to remove some of the scuttle to get to it.

what do people think?

[Alan lig]

Anythings repairable but it is an awkward place just have to cut out the rust and weld it up again in sections ,good luck

[totalnova]

Yeah i think im going to strip the dash out and attack it from the inside, cut out the rust and see what im left with and then take it from there. looks like an early start in the morning.

[totalnova]

I've been looking but can't find anything has anybody got any details pictures of a repair in this area, near side under the dash.

http://rs5.pbsrc.com/albums/y155/totalnova/IMAG1370.jpg~320x480

Just trying to get an idea what I'm in for. Thanks.

[dgbnova#1]

Dash out and make the best you can from the inside

[totalnova]

I keep thinking that it might be easier from the front of the car then from inside, I really need to just get the dash out and see, but just haven't had time to. Thanks.

[Scottcooper85]

It will take about 40mins to whip the dash out but will be worth it. I had similar problems in the same area and got to most from the wheel arch and engine bay but had to do a little in the car too. Check my build thread.

[totalnova]

It will take about 40mins to whip the dash out but will be worth it. I had similar problems in the same area and got to most from the wheel arch and engine bay but had to do a little in the car too. Check my build thread.

Thanks, just had a look now, I know what im likely to be up against cheers mate, just need to find some time to do it now.

[jeremy fisher]

http://i1027.photobucket.com/albums/y337/4539nick/P1000818_zpszqgxpfxa.jpg~original (http://s1027.photobucket.com/user/4539nick/media/P1000818_zpszqgxpfxa.jpg.html)http://i1027.photobucket.com/albums/y337/4539nick/P1000820_zpscp9wapvq.jpg~original (http://s1027.photobucket.com/user/4539nick/media/P1000820_zpscp9wapvq.jpg.html)
http://i1027.photobucket.com/albums/y337/4539nick/P1000822_zpsengtazlj.jpg~original (http://s1027.photobucket.com/user/4539nick/media/P1000822_zpsengtazlj.jpg.html)
http://i1027.photobucket.com/albums/y337/4539nick/P1000823_zps9drsbs3j.jpg~original (http://s1027.photobucket.com/user/4539nick/media/P1000823_zps9drsbs3j.jpg.html)
http://i1027.photobucket.com/albums/y337/4539nick/P1010523_zpshhbni5og.jpg~original (http://s1027.photobucket.com/user/4539nick/media/P1010523_zpshhbni5og.jpg.html)
http://i1027.photobucket.com/albums/y337/4539nick/P1010525_zpsmqwfowua.jpg~original (http://s1027.photobucket.com/user/4539nick/media/P1010525_zpsmqwfowua.jpg.html)
It's the other side, did the battery tray with Corsa servo mod at the same time but hopefully it helps. At the very least it might give you some inspiration.
I had never done anything similar before, just a few patches. Anything's possible though. Try and replace like for like. So if you cut out two skins, replace it with two layers of new metal if that makes sense. Oh and try not to leave the country for a month half way through the job, its hard to get back into it!!
And you'd be amazed how far hot welding spatter and sparks can go. If it wasn't for a well placed fire extinguisher and a bit of luck this would have been a scorched black mess. Cover your seats etc with something fire proof or better still, remove everything.
Good luck.

[totalnova]

Thanks very much, hopefully I'll have some new pictures soon to show how much Ive had to cut out. I think I'll be removing the whole interior to do this job.

[Benn]

Nice repair job, nice metal work fab too.

[dgbnova#1]

Love that looks sweet

[HouseAtreides]

Awesome bit of fab work there - the contours in that section of the bulkhead are particularly difficult to recreate, and you nailed it! The exact same area was beginning to go as a result of rust spreading down from the battery tray on mine, though due to there only being very slight corrosion to the areas where the throttle cable etc feed through, I managed to clean it, treat it, and eventually weld it upon fitting the new battery tray without getting overly involved. Credit to you.

Tony

[totalnova]

I agree that's what I would call a proper job, just hope I'm going to be half that good doing mine.

[jeremy fisher]

Thanks!!
I think pictures always look a bit better than real life but I was chuffed, even more so after the replies on here.
I'm sure you'll be ok, just take your time.
I'm looking forward to see how the engine turns out too. Had a X18XE1 in my shed for a while, keep getting tempted by it but ploughed a bit too much into my current engine and things like lack of aftermarket pistons put me off.

[totalnova]

Well its been a while since I updated this, mostly due to lack of activity over the colder months, but ive pulled my finger out and im getting on with it again.

A few moths ago I picked up some second hand doors that are 100% rot free, thay had polycarb windows in them previously so I need to replace the metal that splits the two windows but thats easily sorted from my rusty set.

http://i5.photobucket.com/albums/y155/totalnova/IMAG1625.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1625.jpg.html)


Anyway back to the rust.......

http://i5.photobucket.com/albums/y155/totalnova/IMAG1370.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1370.jpg.html)

Here is the problem area

So i whipped the dash out, not as painful as i thought it would be and dont think i broke anything to costly.

http://i5.photobucket.com/albums/y155/totalnova/IMAG1560.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1560.jpg.html)

Removed the loom from the bay

http://i5.photobucket.com/albums/y155/totalnova/IMAG1563.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1563.jpg.html)

time to get cutting

http://i5.photobucket.com/albums/y155/totalnova/IMAG1612.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1612.jpg.html)

http://i5.photobucket.com/albums/y155/totalnova/IMAG1616.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1616.jpg.html)

http://i5.photobucket.com/albums/y155/totalnova/IMAG1618.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1618.jpg.html)

and after i gave it a clean up

http://i5.photobucket.com/albums/y155/totalnova/IMAG1624.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1624.jpg.html)

Thats it for now on the Nova.

For anyone interested i got some new alloys for my BMW


http://i5.photobucket.com/albums/y155/totalnova/IMAG1626.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1626.jpg.html)

[totalnova]

Just a small update...
Well had a few hours on the car today, started by making a cardboard template and replicated it into metal this took longer then i thought as it was pain to get it to all line up.

http://i5.photobucket.com/albums/y155/totalnova/IMAG1655.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1655.jpg.html)
I had planned to get much more done but i ran out of gas so i leave it for now

chucked some primer over it to protect it until i can get more gas.

http://i5.photobucket.com/albums/y155/totalnova/IMAG1656.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1656.jpg.html)

you can see i haven't completed the bottom line due to the gas running out.

[totalnova]

Well its been a long since an update so here goes.

Well since i'm working in a single garage to make my life easier I welded up a dolly to make moving the car possible while it has no wheels

http://i5.photobucket.com/albums/y155/totalnova/IMAG1703.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1703.jpg.html)

and got the car up on it

http://i5.photobucket.com/albums/y155/totalnova/IMAG1706.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1706.jpg.html)

As you can see in that picture the rear arch has been repaired by the previous owner.............errr so why have i cut it up?

http://i5.photobucket.com/albums/y155/totalnova/IMAG1725.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1725.jpg.html)

The previous owner had just done the outter arch and hadn't bothered about the inner arch or the sill to say it was rotten was an understatement so i thought i would just cut it all out and start again

I've cut the inner arch to shape but haven't welded it in as my gas hose has split........ Ebay to the rescue, should be here soon.

http://i5.photobucket.com/albums/y155/totalnova/IMAG1781.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1781.jpg.html)

Also I've got loads of new parts I wont list them all just the important bits.

http://i5.photobucket.com/albums/y155/totalnova/received_10155689861435022.jpeg~original (http://s5.photobucket.com/user/totalnova/media/received_10155689861435022.jpeg.html)

Nice f13 gearbox, it was very oily when i got it but ive given it a quick clean up and it will be painted at a later date.

http://i5.photobucket.com/albums/y155/totalnova/IMAG1782.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1782.jpg.html)

Lovely clean SR interior with no rips or bolster wear, not cheap so its been wrapped up until its needed.

http://i5.photobucket.com/albums/y155/totalnova/IMAG1783.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1783.jpg.html)

And the most important bit, the heart

http://i5.photobucket.com/albums/y155/totalnova/Screenshot_2014-11-14-19-14-25_1.png~original (http://s5.photobucket.com/user/totalnova/media/Screenshot_2014-11-14-19-14-25_1.png.html)

[totalnova]

Also i got the chip and immobilizer and engine loom and exhaust manifold and down pipe with the engine for a decent price.

[millworm]

Looking good, can't wait to see it done mate

[totalnova]

Well it might slow down on purchasing parts as I've got a baby on the way now but all I really need now is suspension and fiddly little bits.
Oh let me know when you've sorted the seat brackets please.

[millworm]

Of course, not gonna lie i forgot about them lol, congrats on the baby aswell mate :)

[Rickyb]

love this project keep the updates comingbuddy.
Rick

[totalnova]

love this project keep the updates comingbuddy.
Rick

Cheers im doing my best to not let it drag on, but life always seems to get in the way.

[totalnova]

Been doing bits and pieces over the last few weeks including working on the rear near arch

got the new inner wing welded in

http://i5.photobucket.com/albums/y155/totalnova/IMAG1815.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1815.jpg.html)

All etched up

http://i5.photobucket.com/albums/y155/totalnova/IMAG1818.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1818.jpg.html)

The rust had also made its way into the boot floor so that has been cut out and replaced also tidied up the end of the inner wing

http://i5.photobucket.com/albums/y155/totalnova/IMAG1925.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1925.jpg.html)

Patched up a small hole in the inner wing

http://i5.photobucket.com/albums/y155/totalnova/IMAG1921_1.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1921_1.jpg.html)

Welded in and ground down

http://i5.photobucket.com/albums/y155/totalnova/IMAG1924_1.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1924_1.jpg.html)

Just need to focus on the sill end now and then this corner is finished metal work wise.

[totalnova]

I plan on stripping the whole inner arch back to bare metal before rust proofing it what process would people recommend? I've seen people use loads of different products including red oxide and etch and wax oil. Opinions???

Cheers Nick

[totalnova]

Just a quick update to show the direction I'm heading with the engine.
r1 throttle bodies
http://i5.photobucket.com/albums/y155/totalnova/Screenshot_2015-10-05-20-51-08_1.jpg~original[/URL][/IMG]

[millworm]

Nice man, I just seam seal and then waxoyl once all the welding is done

[totalnova]

Cheers mate, did you manage to get the seat brackets off?

[millworm]

Completely forgot! Shell this weekend so good you reminded me!

[totalnova]

Haha brilliant. Well whip them off and I'll come grab them once it's done. Cheers

[totalnova]

Well I kind of rushed into buying the R1 throttle bodies and as t turns out they are no good to me due to the way they work, so they have been replaced with a much earlier GSXR set up

http://i5.photobucket.com/albums/y155/totalnova/IMAG1938.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1938.jpg.html)

I'm having a manifold made to match the throttle bodies to the x18xe1 engine ill be using. I need to work out what management I will be using, although I've got my eyes on an Omex 600 set up but I haven't made a final decision on that.

Back to the car I'm continuing the strip down, I'm focusing on the rear end for now so off came the rear beam

http://i5.photobucket.com/albums/y155/totalnova/received_10156150572300022.jpeg~original (http://s5.photobucket.com/user/totalnova/media/received_10156150572300022.jpeg.html)

This will be cleaned up and painted and then Poly bushed, I was planning on getting bits powder coated but I need to try and keep cost down where I can now.

Started stripping the sound deadening off as I'll be painting inside and then redoing the sound deadening after to keep it quiet.....ish

http://i5.photobucket.com/albums/y155/totalnova/IMAG1949.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1949.jpg.html)

http://i5.photobucket.com/albums/y155/totalnova/IMAG1950.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1950.jpg.html)

I have more to update and Ill do that soon.
Thanks for looking Nick

[millworm]

Get a set of discs for the axle, the sound defending is awful stuff, I have a screwdriver that is still covered in the back gooey stuff now lol

[totalnova]

I think I'm going to stick with the drum set up on the rear and I found it wasn't to bad removing the sound deadening it cleaned up easily afterwards as well. Did you manage to get them brackets off before the shell went?

[totalnova]

Well heres today's efforts
first off i took out the rear 1/4 windows and windscreen

http://i5.photobucket.com/albums/y155/totalnova/received_10156179709485022.jpeg~original (http://s5.photobucket.com/user/totalnova/media/received_10156179709485022.jpeg.html)

http://i5.photobucket.com/albums/y155/totalnova/received_10156179709770022.jpeg~original (http://s5.photobucket.com/user/totalnova/media/received_10156179709770022.jpeg.html)

To be honest it was a lot easier then I thought it would be, just need to clean up the sealant now.

once that was done i thought i would get back to my rear arch that I've almost completely rebuilt
started like this once i had cut all the rot out

http://i5.photobucket.com/albums/y155/totalnova/IMAG1725.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1725.jpg.html)

And currently left like this

http://i5.photobucket.com/albums/y155/totalnova/IMAG1970.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1970.jpg.html)

Just need to weld the outer arch back and a patch to join the sill and inner wing and then this corner is done as far as the metal work is concerned.

[totalnova]

Oh forgot to add I got some new pistons and conrods

http://i5.photobucket.com/albums/y155/totalnova/IMAG1963.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1963.jpg.html)

These pistons are from a Z18xer engine and have valve pockets as standard

http://i5.photobucket.com/albums/y155/totalnova/IMAG1962.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1962.jpg.html)

Need a good clean up in that pic but these should help with me running some wild cams

http://i176.photobucket.com/albums/w195/tomreid/IMG_1833_zpsnhzh5nbj.jpg~original

You can see in this picture the standard x18xe1 rods on the left and the z18xer rod on the right, you can see they are much stronger. Have to admit I stole this idea and pic from a guy on Mig

[_Tomiboy]

I have the same conrods and pistons. Rev it regulary up to 7500 rpm. Once i made bad shifting and it revd over 9500, but it works. :)

[totalnova]

What engine are you running them in? And what spec?
cheers Nick

[_Tomiboy]

C14SE block, x18xe1 crank and oilpump, z18xer pistons and conrods, arp bolts, heavy modified c16se head with 40/32,5 risse valves, solid lifters, double springs, ast18 cam, dbilas 40mm throttle bodys, c20ne ecu and loom, v6 blue injectors, big 4-2-1 exhaust manifold.

[totalnova]

Sounds like a weapon, bet it goes well.

[gary_126]

Nice read this! Ive also a z18xe lined up for my nova (been collecting parts for 3 years, including the car, and still havent started work on it yet) ill get there, lol

[totalnova]

Just be careful with the z18xe as I'm sure your aware they are fly by wire, there are ways around this though.
Thanks for the comment, Nick

[totalnova]

Oh also received my new inlet manifold to suit the GSXR bodies made by [URL="http://www.danstengineering.co.uk/ can't rate them enough very very happy with what I've received and I'll post pictures tomorrow.
Nick

[tom reid]

lol
Oh forgot to add I got some new pistons and conrods

http://i5.photobucket.com/albums/y155/totalnova/IMAG1963.jpg (http://s5.photobucket.com/user/totalnova/media/IMAG1963.jpg.html)

These pistons are from a Z18xer engine and have valve pockets as standard

http://i5.photobucket.com/albums/y155/totalnova/IMAG1962.jpg (http://s5.photobucket.com/user/totalnova/media/IMAG1962.jpg.html)

Need a good clean up in that pic but these should help with me running some wild cams

http://i176.photobucket.com/albums/w195/tomreid/IMG_1833_zpsnhzh5nbj.jpg

You can see in this picture the standard x18xe1 rods on the left and the z18xer rod on the right, you can see they are much stronger. Have to admit I stole this idea and pic from a guy on Mig

The guy on mig that you stole this picture from is aware you stole it and doesn't mind lol

[totalnova]

lol

The guy on mig that you stole this picture from is aware you stole it and doesn't mind lol

Haha brilliant, cheers

[totalnova]

http://i5.photobucket.com/albums/y155/totalnova/Screenshot_2015-11-07-22-33-29_1.jpg~original (http://s5.photobucket.com/user/totalnova/media/Screenshot_2015-11-07-22-33-29_1.jpg.html)

[totalnova]

As promised a pic of the manifold made to fit the GSXR bodies

Made by Danstengineering.co.uk

[millworm]

Looks good really coming along since I last saw it, need to finish my zetec build and start me c20let rebuild!!!!

[_Tomiboy]

Have you measured the conrod weight? The china H-profile is 439 gramm.

[totalnova]

No I haven't touched the conrods since I got them, there still sitting in a box in my garage waiting to go to my engine builder who already has my engine, if he says they are no good then I won't be using them.

[Mxcrazy]

Z18xer conrod, 444g +\- ��

[ledpen]

Cool build mate

[Mxcrazy]

I have started a thread in mechanical about the z18xe/x18xe1 engine.

interestingly the z18xer piston/rod combo will sit 1.3mm proud of where the z18xe/x18xe1 piston/rod combo will from my measurements.

[totalnova]

Sounds like it will need machining then thanks for the info.

[Mxcrazy]

I am going to look at a decompression plate to bring the deck height up to suit. I have vernier pulleys anyway so no problem in that area.

[totalnova]

Just a quick one

http://i5.photobucket.com/albums/y155/totalnova/IMAG1977.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1977.jpg.html)

Welded in sill piece

http://i5.photobucket.com/albums/y155/totalnova/IMAG2009.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2009.jpg.html)

Inner arch finally finished, etch primed and seem sealed and then painted over although you cant see that in the pic because i forgot. Not the best looking repair but it wont be seen so i can live with the fact its strong and done properly.
This was a real mess and was rusted quite badly after i cut all the rust out it looked like this so i'm glad its finally done

http://i5.photobucket.com/albums/y155/totalnova/IMAG1725_1.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1725_1.jpg.html)


ive welded in the outer arch but its nowhere near finished yet so i'll leave it there

[totalnova]

it feels like a mini milestone,

http://i5.photobucket.com/albums/y155/totalnova/received_10156286968180022.jpeg~original (http://s5.photobucket.com/user/totalnova/media/received_10156286968180022.jpeg.html)

http://i5.photobucket.com/albums/y155/totalnova/received_10156286998185022.jpeg~original (http://s5.photobucket.com/user/totalnova/media/received_10156286998185022.jpeg.html)

First time I've ever done anything like this, its not finished just yet as far as the bodywork goes as I don't want to fill my garage with filler dust until I can do the whole car. I feel like ill be able to do the metalwork on other side no problem at all now and probably half the time.

[millworm]

That looks really well done mate, come a long way from when I saw it. Just ordered the rebuild bits for mine today so hopefully I'll can get started on it

[jimbob-mcgrew]

done a good job on that rear wing, looks tidy :thumb:

[Benn]

Looks like a good job. Well done.

[totalnova]

Cheers guys, just sitting here now thinking what to do next, offside rear arch or engine bay. Decisions decisions

[gary_126]

Just be careful with the z18xe as I'm sure your aware they are fly by wire, there are ways around this though.
Thanks for the comment, Nick

yeah, it was a 40k engine i got for a good price (worst case i was going to convert it to x18xe1 inlet and ecu) I had figured most of the z18 management out, but it was so long ago ive since forgotten. Very little info on retro fitting this engine, but it must be do-able. I once saw an advert/article for a company that made canbus ecu's (including vauxhalls) for older cars, but ive never managed to find it again.

[totalnova]

firstly progress has slowed down on this due to a new arrival

http://i5.photobucket.com/albums/y155/totalnova/IMAG2075.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2075.jpg.html)

I have been able to get a few bits done, although not as much as I'd have hoped, its mainly just cutting rot out and painting

started by cutting out the rusted inner and outer offside arch

http://i5.photobucket.com/albums/y155/totalnova/IMAG2037.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2037.jpg.html)

Then started removing under seal, guess what I found.....

http://i5.photobucket.com/albums/y155/totalnova/IMAG2079.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2079.jpg.html)

A nice hole that got a bit bigger

http://i5.photobucket.com/albums/y155/totalnova/IMAG2087.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2087.jpg.html)

I'm pretty certain I've now removed all rust from the car so the next few updates should contain plenty of welding

I've also been doing some painting, only have a picture of the rear beam at the moment but all suspension components that need painting will be done silver
The rear beam will be treated to new poly bushes and brakes and cables

http://i5.photobucket.com/albums/y155/totalnova/IMAG2088.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2088.jpg.html)



One last thing, this white tube that the tank breather goes through how does it come out?

http://i5.photobucket.com/albums/y155/totalnova/IMAG2086.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2086.jpg.html)

[paul james]

MG]

One last thing, this white tube that the tank breather goes through how does it come out?

http://i5.photobucket.com/albums/y155/totalnova/IMAG2086.jpg (http://s5.photobucket.com/user/totalnova/media/IMAG2086.jpg.html)

Not easily, thats how! Took me a while to get mine out with pliers, and it got mangled in the process. Like yours my Nova had rusted around that area, So I welded some metal pipe in there instead.

Congrats on the baby, very cute!

[totalnova]

Not easily, thats how! Took me a while to get mine out with pliers, and it got mangled in the process. Like yours my Nova had rusted around that area, So I welded some metal pipe in there instead.

Congrats on the baby, very cute!

Thanks very much and yes he is very cute, gets his looks from is old man.

Guess Ill have to just try harder to get the tube out,
thanks.

[8valve-craig]

Congratulations, he's so cute.

If you decide you want to sell me those doors back il take them in a heartbeat, at your own price.

[totalnova]

I very much doubt I'll need to sell the doors mate, as you well know they are perfect :thumb:

[Novasport]

Thanks very much and yes he is very cute, gets his looks from is old man.

Guess Ill have to just try harder to get the tube out,
thanks.

If you destroy it I have a new one spare here. It is likely you will destroy it though lol

[totalnova]

Managed to get a few hours on the nova today, started welding in a patch in the rear of side arch

started with some CAD for the first skin

http://i5.photobucket.com/albums/y155/totalnova/IMAG2123.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2123.jpg.html)

Transferred to metal

http://i5.photobucket.com/albums/y155/totalnova/IMAG2124.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2124.jpg.html)

and welded

http://i5.photobucket.com/albums/y155/totalnova/IMAG2127.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2127.jpg.html)

Ground flat so I could get the second skin on top

http://i5.photobucket.com/albums/y155/totalnova/IMAG2128.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2128.jpg.html)

Second skin welded in a ground flat

http://i5.photobucket.com/albums/y155/totalnova/IMAG2130.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2130.jpg.html)

still a bit more to do on this corner like repairing the sill end and then weld on inner and outer skins, hopefully it will be done before the end of the month.


Some purchases

Some bits for the engine
http://i5.photobucket.com/albums/y155/totalnova/IMAG2133.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2133.jpg.html)
cams
http://i5.photobucket.com/albums/y155/totalnova/IMAG2134.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2134.jpg.html)

This needs a good polish but I got it very cheap considering what they go for

http://i5.photobucket.com/albums/y155/totalnova/IMAG2136.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2136.jpg.html)

More painting

http://i5.photobucket.com/albums/y155/totalnova/IMAG2137.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2137.jpg.html)

Thats it for now.

[millworm]

Mmm shiny expensive parts, can't wait to see this done I live them engine especially since the old girl got a c sri

[totalnova]

Yeah they are a great engine, I had one in an old Astra g and they really do have a decent amount of tourque
I really can't wait to get it finished but I'm just chasing rust at the moment, I really should have waited and found a better shell, but at least I know this will be solid once it's finished.

[millworm]

Will be worth it for peice of mind when done, also congrats on the littleun

[josh-sri]

Looking good mate coming along nicely, the work on the shell can be a pain but once done right will last ages, I nearly gave up on mine but so glad I didn't now, would take ages to find a solid clean shell I imagine.

[slimtater]

Nice thread this - enjoyed catching up. Sounds like our projects are very similar - some of the rot areas look very familiar! lol

[totalnova]

Just a mini update,

got the sandblaster out and gave the drum back plates a good seeing to, they had seen better days

http://i5.photobucket.com/albums/y155/totalnova/IMAG2284.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2284.jpg.html)

After the blasting I etched primed and then gave them a couple of coats of paint

http://i5.photobucket.com/albums/y155/totalnova/IMAG2287.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2287.jpg.html)

very pleased with how these came out.
I had ordered new shoes, cylinders and drums so set about fitting it all

http://i5.photobucket.com/albums/y155/totalnova/IMAG2291.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2291.jpg.html)0

just need to press the bearings into the drums and find the correct handbrake cables and fit some poly bushes and it can be wrapped up until the car is ready

[totalnova]

I also made a start on the inner arch

http://i5.photobucket.com/albums/y155/totalnova/received_10156623747490022.jpeg~original (http://s5.photobucket.com/user/totalnova/media/received_10156623747490022.jpeg.html)[/IMG]

[millworm]

Some good progress there mate, certainly more than I've managed to do recently, although I did buy 2 more cars :tard:

[totalnova]

Few bits done to the nova, the engine is currently being rebuilt at my mates

http://i5.photobucket.com/albums/y155/totalnova/IMAG2333.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2333.jpg.html)

And im tarting up the rocker cover so it's nice and shiny


http://i5.photobucket.com/albums/y155/totalnova/IMAG2387.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2387.jpg.html)

ive been carrying on welding, but it's taking a lot longer then I had hoped.
Still need to cut the circular hole for the fuel breather to go


http://i5.photobucket.com/albums/y155/totalnova/IMAG2394.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2394.jpg.html)

and I've done as much to the inner wing as I can until I finish were it meets the sill and the bumper end

http://i5.photobucket.com/albums/y155/totalnova/IMAG2395.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2395.jpg.html)

Also took the underseal on the rear chassis legs and was very happy with what I found

http://i5.photobucket.com/albums/y155/totalnova/IMAG2397.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2397.jpg.html)http://i5.photobucket.com/albums/y155/totalnova/IMAG2399.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2399.jpg.html)

[Iain]

Chassis legs look good! Welding will be worth it in the end

[totalnova]

It's about time I had some good luck with this shelll, but it feels like I'm making progress and getting some of the smaller jobs done here and there when I have an hour free.

[Benn]

Chassis legs do look nice and clean.

[totalnova]

We'll I should probably update this as it been a while, not much has happened due to Daddy duties and work but I've taken every chance I've had to get in the garage and get some jobs done.

Firstly ordered my alloys, probably didn't need them yet and they are taking up space but i couldn't resist.

http://i5.photobucket.com/albums/y155/totalnova/IMAG2423.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2423.jpg.html)

And I've been carrying on with the welding. I had to completely rebuild the sill end of the inner wing, I shouldn't be surprised I had to do the same thing on the other side.

http://i5.photobucket.com/albums/y155/totalnova/IMAG0118.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG0118.jpg.html)

And then it was time to put the outer sill skin on

http://i5.photobucket.com/albums/y155/totalnova/received_10157189810245022.jpeg~original (http://s5.photobucket.com/user/totalnova/media/received_10157189810245022.jpeg.html)

Build the spot welds up and it ends up like this.

http://i5.photobucket.com/albums/y155/totalnova/IMAG0119.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG0119.jpg.html)


Welds ground away and etch primer, after a layer of filler it will looks great (I hope)
http://i5.photobucket.com/albums/y155/totalnova/IMAG0124.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG0124.jpg.html)
Just need to put the outer skin on and then I'll move into the engine bay and weld up the rust holes I've already cut away.
Nick

[Benn]

You can get away with a spot weld then a small gap, you dont have to over lap them.

Nice work.

[millworm]

Them whells look smart mate, made a bit of progress on mine recently I should update!

[totalnova]

You can get away with a spot weld then a small gap, you dont have to over lap them.

Nice work.

Cheers Benn, I've always overlapped the welds it's just the way I was taught feels lazy having little holes. :thumb:

[totalnova]

Them whells look smart mate, made a bit of progress on mine recently I should update!

Yeah I love the wheels, can't wait until I'm able to actually get them in the car. Oh I'm sorry to hear about your daily, you haven't had much luck with your dailys cars since I've known you.

[Benn]

Cheers Benn, I've always overlapped the welds it's just the way I was taught feels lazy having little holes. :thumb:

I get that. just some times saves on warping and filling after.

[totalnova]

Well a small update, been working on the car as when I can and I've finally got the offside rear arch finished, one thing i will say is the repair panels are shit and dont really line up where they should but its finally done and i can forget about it.

anyway some pics

http://i5.photobucket.com/albums/y155/totalnova/IMAG0150.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG0150.jpg.html)

Got the sill end on.

http://i5.photobucket.com/albums/y155/totalnova/IMAG0173.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG0173.jpg.html)

The bumper end, reason they was cut was to get a perfect fit.

and a light skim of filler.

http://i5.photobucket.com/albums/y155/totalnova/IMAG0176.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG0176.jpg.html)

the filling and sanding will be left for now as I dont want to fill my garage with dust.

other little jobs have been done including welding on the 60/40 rear seat brackets and other little fiddly jobs not worthy of pics.
Nick

[totalnova]

and yes i really do need to clean my garage. ;)

[Benn]

Filler shouldn't be put on paint. Only bare metal. Nice work tho.

[millworm]

Looks well mate need to order more for mine

[totalnova]

Filler shouldn't be put on paint. Only bare metal. Nice work tho.

Cheers mate, I do know this and it will all be sanding back when I actually do the body work, the layer of filler was just to make sure it was all relatively flat and so I could see I didn't need to re do anything. All the body work will be done after I've finished welding. :thumb:

[totalnova]

Been cleaning up the rear end underside, I was originally going to paint it body colour but in the end I decided I'd paint it black.
Anyway I got the wire brush out and the sander and cracked on with it.

http://i5.photobucket.com/albums/y155/totalnova/IMAG0191.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG0191.jpg.html)

And primer

http://i5.photobucket.com/albums/y155/totalnova/received_10157430888205022.jpeg~original (http://s5.photobucket.com/user/totalnova/media/received_10157430888205022.jpeg.html)

[totalnova]

The black needs another coat so I'll post that pic once it's done. The next job will be underneath and rear arches being undersealed. Then I'll move onto the engine bay.

[millworm]

I ended up hameriting mine in the arches and underneath, I assume your spraying?

[totalnova]

Yes I'm spraying, I did attempt to do it with the compressor, but found it to difficult doing it on my back with a gravity feed gun, so reverted to rattle cans.

[totalnova]

Well its about time I updated this, as with most of us life has been getting in the way and things like working and DIY seem to be more pressing and this ends up taking a back seat, but I've been managing a few hours here and there to keep my hand in.

I had an issue with rust on the lower cross member so I braced it up and cut out the rusty member

http://i5.photobucket.com/albums/y155/totalnova/IMAG0224.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG0224.jpg.html)

I managed to get my hands on a genuine replacement so I set about welding it in.

http://i5.photobucket.com/albums/y155/totalnova/IMAG0248.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG0248.jpg.html)

I still need to weld in some strengthening tabs like it has factory and then I will weld on the lower valance

Other little jobs I've been doing includes cleaning up bits like hub carriers

http://i5.photobucket.com/albums/y155/totalnova/Mobile%20Uploads/IMAG0374.jpg~original (http://s5.photobucket.com/user/totalnova/media/Mobile%20Uploads/IMAG0374.jpg.html)

I've got new bearings and hubs to be pressed in

I've also been doing some dirty jobs like finishing off painting underneath

http://i5.photobucket.com/albums/y155/totalnova/IMAG2427.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG2427.jpg.html)

I've also done two of the four inner wings

http://i5.photobucket.com/albums/y155/totalnova/IMAG0225.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG0225.jpg.html)

Not the best picture but you get the idea

http://i5.photobucket.com/albums/y155/totalnova/IMAG0310.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG0310.jpg.html)

This has since been painted black but i don't have a picture so primer will have to do, the car has now been pushed up next to the other side of the garage so I can work on the near side.

I've also been doing some shopping and trying to get all the bits I need to rebuild this thing, but the paIt's list is ever increasing and so to is the spec.

These arrived about a week ago

http://i5.photobucket.com/albums/y155/totalnova/IMAG0342.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG0342.jpg.html)

And of course you can't be putting rubber hose back on

http://i5.photobucket.com/albums/y155/totalnova/Mobile%20Uploads/IMAG0380.jpg~original (http://s5.photobucket.com/user/totalnova/media/Mobile%20Uploads/IMAG0380.jpg.html)

And I've also got some silicone hoses from mr peester from his z18xe powered featured car, I know there was a few people after them so I can only apologise.

There is probably more I've missed out but that sort of brings things up to date.
Cheers Nick.

[millworm]

Big progress, lucky my member only.had a little hole in it. Still need to get 4 pots for mine too! Looking good man well done

[totalnova]

Yeah it's definitely getting there and I can see the light at the end of the tunnel, I know I could finish it this year but it all depends on money.

[totalnova]

Just a very small update, spent an hour on the garage today as I wanted to weld in a rear strut brace, I had bought an aluminium rear brace that bolts in, but after thinking about it I thought some nice thick steel would be better. I cut the brace to length weird on some spreader plates and then spot welded the whole thing into place.

http://i5.photobucket.com/albums/y155/totalnova/IMAG0418.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG0418.jpg.html)

Not bad for about 10 pound.
Nick

[Benn]

Nice, glad its a proper brace. Feels much better with them.

[totalnova]

Nice, glad its a proper brace. Feels much better with them.

Cheers benn

[totalnova]

Well time for an update, I've been plodding along with this and there's not a lot left to do on the shell now, I'd love to get it into a paint booth for summer, but that might be tad optimistic.

Anyway this is where I'm at.
A while ago I found some lovely rust under the dash

http://i5.photobucket.com/albums/y155/totalnova/IMAG1370.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1370.jpg.html)

So got the cutting discs out which resulted in this

http://i5.photobucket.com/albums/y155/totalnova/IMAG1616.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1616.jpg.html)

And this

http://i5.photobucket.com/albums/y155/totalnova/IMAG1612.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG1612.jpg.html)

I left it like this for a while and got on with other jobs, but last fews weeks ivery been getting on with it

http://i5.photobucket.com/albums/y155/totalnova/IMAG0562.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG0562.jpg.html)

And finished and cleaned up

http://i5.photobucket.com/albums/y155/totalnova/IMAG0573.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG0573.jpg.html)

And the top side

http://i5.photobucket.com/albums/y155/totalnova/IMAG0493.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG0493.jpg.html)

And then I had to weld this awkward wanker back in
http://i5.photobucket.com/albums/y155/totalnova/IMAG0609.jpg~original (http://s5.photobucket.com/user/totalnova/media/IMAG0609.jpg.html)
just need to flat these welds back and a light skim of filler and it will be ready to paint.
Only welding left to do now is under the battery tray.
Thanks for reading , Nick

[totalnova]

Well since the photobucket change of policy I e been a bit slow updating this, I've even not really bothered taking as many pics as I normally do, but I've opened a flickr account now so I'll try and keep this uoto date.

I've done a few bits over the last few months I've been focusing my efforts on the engine bay trying to get it to a stage were its ready to paint.

I've only got a few pics of the front valance and none of the fitting process as its just a few plug welds and making sure it all lines up as it should.
http://i.imgur.com/ut8GF3O.jpg

so wired brushed the engine bay to bare metal making sure no rust has been missed.

http://i.imgur.com/wTHYZDG.jpg

Since this picture was taking I've stitched welded the bay and etched primed it, I'll get pictures for the next update.
I've also been acquiring parts, got a new rear bumper as mine had broken plastic lugs.

Also been doing small jobs like filling unneeded mk1 bumper holes on the rear wings

Before
http://i.imgur.com/G3fXrkf.jpg

After

http://i.imgur.com/dUendxf.jpg
I'll try and sort the previous pics out when I get a few hours spare.
Cheers Nick

[totalnova]

Well it looks like I've not worked out the pic hosting as well as I thought I had lol
I'll have another go

[total_vauxhall]

Imgur or tapatalk pal works instantly

[totalnova]

I've uploaded a few pics on to this so I'll try a little longer, cheers.

Edit, went with imgur in the end, so much easier. Cheers

[totalnova]

Bare metalled the whole rear corner and started on the filler work, I'm hoping to get the car painted just after Christmas.

https://i.imgur.com/mCXd6kt.jpg

[Stuart]

Patched up the pics in the thread (ignored quoted one lol) Hope that helps

[totalnova]

Cheers Stuart, I've been putting off fixing this thread and you've saved me doing it, cheers.

[totalnova]

May as well give a little update to where I'm at with the car while I'm here, the car is booked into the body shop to be painted in January, as soon as it's back the build can begin, being realistic I'm hoping to have it finished by spring 2019, the only expensive stuff I have to buy now is the engine management system.
Just recently acquired my new Gaz coilovers, took just over two weeks to arrive, great service.
Plus I've finally got hold of a decent gsi front bumper.

Next update the car should be painted. Loads of pics then.

[totalnova]

well for the first time in a year and a half The car is off it's frame and has it's suspension and wheels back on is and is back on the ground.

https://i.imgur.com/w9MqTjv.jpg

The reason for this is because it's off to the bodyshop to be painted
https://i.imgur.com/8gD1FGp.jpg

so excited and can't wait for it to be done.

[Stuart]

yay

[totalnova]

Well the car is well onto it's way of being finished at the bodyshop, have to say I'm over the moon with what they have done and their professionalism, I've heard so many story's of bodyshops letting people down and taking months and months to complete work, I'm glad to say after doing my research I found a diamond, if anyone lives near north Hampshire and needs a bodyshop just ask and I'll pass on the details.

Anyway less talk, let's see the pics

https://i.imgur.com/Tvm7wxY.jpg

https://i.imgur.com/DZPSFcp.jpg

https://i.imgur.com/fWoagxS.jpg


https://i.imgur.com/tjr8Eqc.jpg

https://i.imgur.com/1IYkwpu.jpg

https://i.imgur.com/apj70Km.jpg

https://i.imgur.com/eSwQ4GI.jpg

https://i.imgur.com/BeZXTD7.jpg

https://i.imgur.com/BPgebhD.jpg

https://i.imgur.com/TzfLOy2.jpg

I really am over the moon, it's taken me 2 and a half years to get to this point and I've learnt a lot along the way.
Now I get to put it all back together again and start putting on all the expensive bits I've been gathering.
Oh if anyone is wondering the colour is VW cornflower blue.
Nick

[millworm]

Looking smart mate, really has come a long way since I saw it best part of 2/3 years ago!

[totalnova]

Yes it been a long journey and I've learnt a lot along the way, looking forward to bolting bits back on.
How's your saloon?

[millworm]

It'll be a real gem at the end mate! It's still waiting for me to build my fiesta, may buy the turbo this month as a treat. Want to pull the engine again and change some bits I done

[torquey]

Thats Really nice !

[totalnova]

Thats Really nice !

Cheers.

[totalnova]

Well the car is home and I've started fitting bits.

Got the steering rack and column fitted plus headlights the bonnet and wings haven't been screwed sown tight as I need to sort out the shut lines.

https://i.imgur.com/eQq3keI.jpg

https://i.imgur.com/fjxjHyc.jpg

Next jobs are to get the pedals and brake servo fitted, then I can fit the brake lines.

[millworm]

Really looking forward to seeing this done man!

[totalnova]

You and me both, spring 2019 is the deadline

[Benn]

Oooo that looks great!

[totalnova]

Cheers Benn,
Front end is coming together now, just need an extra pair of hands to set the shut lines with the bonnet and the front end will be done.


https://i.imgur.com/jBaIJKP.jpg

[total_vauxhall]

Nice work pal

[torquey]

Loving the colour very nice.

[BRoadGhost]

It would be interesting to know who designed the MK2 face - it is good imo

[totalnova]

I have to admit, I love the way it looks, but I very nearly went with the mk1 snow plough look. Glad I didn't though because in my opinion it looks bloody awesome.

[totalnova]

Time for a small update, got the tyres fitted to my alloys and got them fitted, I love the white wheels with the blue paint.

https://i.imgur.com/6gTek27.jpg

https://i.imgur.com/c54d2G2.jpg

And finally at the second attempt I got my windscreen in, the first attempt ended in failure with the windscreen only fit for the bin after it cracked :roll:

But I managed to find a brand new screen and I got it fitted today no dramas this time.

https://i.imgur.com/AwyHLS8.jpg

[totalnova]

I'd love to get it finished for the summer, the list is still quite long, although it does now look like a car.
Brake lines and underseal will be the next jobs.

[totalnova]

Mini update, engine is ready to go in, but the car isn't quite there yet, still got a few bits to do yet before it can go in.

https://i.imgur.com/yFz9YrR.jpg

https://i.imgur.com/U6VEpH1.jpg

Hopefully it will be in the car in a few weeks.

Also I've been on my back getting the underside finished off, it's now ready to be underseal, then I can run the brake and fuel lines, I can see the light at the end of the tunnel now.

https://i.imgur.com/eOVhGnW.jpg

https://i.imgur.com/uGJcEWO.jpg

Hopefully the next update will be the engine going in.
Thanks for looking, Nick.

[8valve-craig]

Excellent work, Car looks stunning.

[totalnova]

Cheers Craig, it's getting there.

[Iain]

This looks awesome!!!

[millworm]

Looking miles apart from when i last saw it what 4 years ago? Very jealous

[Benn]

Underside looks great tidy.

Is looking good now its coming together, liking the white wheels on blue too.

[totalnova]

Time for a small update, got the whole of the underside undersealed, god awful dirty job and I was covered in the stuff, but it went on nice and evenly and has left a lovely finish, just hope it keeps the dreaded tin worm at bay.

https://i.imgur.com/2YTXOBE.jpg

I won't bore you with more pics of underseal, plus it was hard to get a decent shot of the underside.

Also my engine is now finished and is ready to go into the car, hopefully this will happen next week but I never know when I'll get to get into the garage and play

https://i.imgur.com/YCcRaZ2.jpg

Also gave the gearbox a little clean up, I wasn't going to bother but my mate made me
Primed
https://i.imgur.com/KwT8vfn.jpg
And painted
https://i.imgur.com/3bvSwWl.jpg
Also changed the release bearing and have a new clutch so it's all ready to go in.
Cheers Nick.

[millworm]

Loving it, little touches like the gearbox make the car that much better

[totalnova]

Time for a major update

The day started of with a decent breakfast (Egg and Bacon) as I knew I would be spending most of the day on the car. Once my younger brother had turned up we cracked on getting the engine and the gearbox together, no dramas there we cracked on and got the engine on the lift, and proceeded to out in in through the top, I'll let you decide if that's the correct way.

https://i.imgur.com/O7xVuUL.jpg

It all went pretty smoothly, just a little wiggling and jiggling to get all the bolts lined up, but we got there.

https://i.imgur.com/NzO3krU.jpg

And it looks bloody brilliant if I do say so.

Ive also managed to get the interior in, put a load of sound deadening inhttps://i.imgur.com/LMa7HQa.jpg

Loads more went in after this picture and I also put a new foam carpet underlay in as well before the carpet went on top. Then I got all the seats and dash in.

https://i.imgur.com/CDMyuLm.jpg

Loads more still to do on the car and I can't wait to get the engine started.
next update will hopefully involve some wilwoods and drive shafts.
Nick

[Seppy]

Car looking really well pal .

[millworm]

Big leap forward there mate!

[totalnova]

Yeah it's really getting there, I'm not sure if I should just pull my finger out and get it done, or take it steady and have it done for the next show season, there really isn't that much left to do.

[totalnova]

Engine bay is starting to fill up.
https://i.imgur.com/uLuLyKQ.jpg

[scottmasterton]

Looking Great!

[totalnova]

Well it's been an expensive month, I finally got to the stage where I needed to fit my Wilwood calipers, nothing to difficult, they weren't a perfect fit and some grinding to clear the hub knuckles was needed, but nothing to major, anyway once they was on I hit another snag

https://i.imgur.com/bxr2jd7.jpg

The revolution alloys I had wouldn't clear the calipers
:confused: these are supposed to be Motorsport alloys and I assumed they would fit as the Wilwood dynamite kit isn't a massive setup.

So I needed new wheels, I've always said I would never fit speedlines to my car, I do think they look nice, just far too common, but what have I done.

https://i.imgur.com/jwQwk4Q.jpg

Aha, so not what you was expecting, I really like these and they clear the calipers fine.
So I had some Goodyear f1s fitted and put them on the car.

https://i.imgur.com/pfJJa2z.jpg

Hopefully the next update will be the engine running.

[totalnova]

Gave the car a quick wash after I changed the wheels

https://i.imgur.com/z51Q5om.jpg

[House]

What are the wheel sizes fella? I’m running these in 15x7 ET 45 I believe, clear my Alcons on a 285 disc no probs

[totalnova]

The revolution alloys are 15x6 it's hard to explain in words but they was catching on the alloys closer to the lug bolts rather then the outside, if they was bigger say 270mm they would have fit. You can actually see in the picture of the brake where it has taken the paint off the caliper.

[House]

Yeah I understand, the inside of the wheel is slightly dished and the part of the calliper closest to hub touches the wheel. But if the disc was bigger then it would move the calliper further out and more into the dish of the wheel.

Let me know if you're thinking of moving those wheels on if they don't suit your needs.

[totalnova]

I am actually thinking of selling them, PM me if your interested. They current have Nangkang ns2r 195 50 15 tyres and wheel and tyres have done zero miles, but had a few marks from being on the car

[boffer8]

Look gorgeous, would also be interested if your not going to use them...

[totalnova]

Look gorgeous, would also be interested if your not going to use them...

Sorry mate house already has the wheels.

[boffer8]

haha no worries.... look forward to seeing what you put on it next.... looked sweet on those...

[House]

Sorry Boff!!

I might have some Speedline Corse 15x7 ET 45 4x100 in Anthracite available, only done one trackday

[totalnova]

I've neglected this thread, but I have been chipping away at the list of jobs.

Yesterday I took the car to my exhaust place and had my downpipe done, not cheap but so much better then bodging something together

https://i.imgur.com/CkRIkA0.jpg

Off she goes, I rented the transporter as it was cheaper then having someone else move it for me.

And the money shot.

https://i.imgur.com/7MyiayT.jpg

The whole system is now custom and I opted for a sports cat to keep the gasses flowing, I also had the boss for my wide band sensor welded in.

The car is now insured and I need to get the last few bits sorted and it should be on the road.

[millworm]

Sweet! Are we going to see it at retro rides weekender?!

[totalnova]

Sweet! Are we going to see it at retro rides weekender?!

What's the dates? I do need to try and set my self a target to have it ready by.

[millworm]

18/19 may

[totalnova]

18/19 may

All going well I'll be there.

[millworm]

Sweet, look forward to seeing it!

[totalnova]

https://youtu.be/DbHbvOPVLVM

Quick video of the first start up.
Very happy, just a few more jobs to get done and it will be in for an MOT

[millworm]

Sounds good! Just on a base map?

[totalnova]

Sounds good! Just on a base map?

Yeah, just a base map for now. I'm going to be making a few tweaks to the engine setup before I have it set up, but more on that in the next update.

[millworm]

Sweet, wont be long untill we see it then

[totalnova]

Well, I've had a slight change of plans, the car hasn't even turned a wheel yet, but I've decided the gsxr throttle bodies are not upto the job, just feels like a bodge and it will never be perfect.

So I've splashed out

https://i.imgur.com/RRZjBJu.jpg

Currently having a new manifold made and will be fitted to the car once I have all the bits I need.

[House]

Excellent!!!!

[millworm]

Porn!

[totalnova]

https://i.imgur.com/7wqMewq.jpg

Just taken it around the block, first drive for over 4 years, brakes need some work still and I need to sort the idle out, but I'm over the moon, so so happy

[millworm]

Looks immaculate mate, pleased for you! Going vboa then?

[totalnova]

Looks immaculate mate, pleased for you! Going vboa then?

No unfortunately I have to work, I think I've missed most of this year's show season, might just wait until next year now to show it.

[millworm]

That's fair enough man, gives you ample time to iron out any little issues with it being a fresh build

[totalnova]

Pic of the first fill up, drives like shit at the moment but it's off to be mapped on Wednesday, can't wait.

https://i.imgur.com/X82tXFc.jpg

[millworm]

Premium stuff i hope!

[totalnova]

Only the best lol

[totalnova]

Well after what can only be described as a disaster last year, with my engine not being as healthy as it should have been I had to pull it out and put a new one in, I didnt bother doing anything to the new one, except clean and paint it, fit my cams and do the cam belt and change some gaskets.
It's now looking all good again
https://i.imgur.com/K3V2K0V.jpg

It never made it on the rollers last year due to the engine. But I'm booked in to be mapped on July 14th so hopefully all will go well and I'll be flying around in this finally.

Also it just passed its MOT so that's sorted for the year
https://i.imgur.com/nkvuAmi.jpg

Tester was very happy with it, no advisories.

https://i.imgur.com/TRc5gzy.jpg

Only things left are to fit my gsi spoiler and side skirts, plus I'd like to do something with the interior, maybe a retrim in the future.
I'll update this after the dyno session.
Nick

[totalnova]

Well its been a while since I updated this, a lot has been going on in the back ground, just when I thought the car was done it kicked me in the balls more then once.
So the car was done, just needed mapping to get it running correctly, so after waiting what seemed an age to get its turn on the rollers, it was finally my turn. So we had an issue with the crank sensor which in the end turned out to be the loom, two wires back to front but it was soon sorted and sent back.
Attempt two, this is where its gets interesting after having a little play but still not running right the the car suddenly dies, long story short the valve has come into contact with a piston causing some damage to the piston.

https://i.imgur.com/KJjaB5p.jpg

After leaving it to sit for a few weeks I decided to just throw an engine from a scrapped car in it and get it going, so onto ebay I went an got one delivered on a pallet, got it all cleaned up and put it in, started it up and............ knock knock knock knock knock, I turned it off and went it inside and sulked.

So only one thing for it, order a rebuild kit, new pistons, new rings, bearings, gaskets, the lot. I rebuilt it in my garage and got it slotted into the car and it started first time, success.

https://i.imgur.com/YcJWa3V.jpg

Then it had a wheel alignment

https://i.imgur.com/OPDBmiU.jpg

So back to the dyno, finally all was well and the car made a healthy 146bhp, this is a 30bhp more then the 116bhp it came with from the factory. Plans for the future are to get my cams sorted out as this engine is running standard ones and have the head flowed, but for now I'm just going to enjoy it.

https://i.imgur.com/ZLPyqLf.jpg

Nick

[The Simps]

Sounds like quite the emotional rollercoaster!

Were you able to diagnose why the valve hit??

[totalnova]

It had catcam camshafts in it and it was on standard cam sprockets, all timed correctly. I havent looked into it to much and I dont want to sling mud, but something isn't correct with them

[totalnova]

So back on the dyno today, had some issues last time so had to go back

https://i.imgur.com/D0MY0SI.jpg

36hp more then standard, I could probably get another 15 with cams and headwork, but to be honest I'm happy with how it is.
Just love driving the thing
Nick

[Will F]

Torque looks decent too - nice and useable!

[millworm]

Will be great fun to drive with that power on a nice revvy engine

[totalnova]

Just adding the little cosmetic bits.
Picked up some window trims yesterday in really good condition.
Before

https://i.imgur.com/QbIQ0Pg.jpg

After

https://i.imgur.com/fwXujZH.jpg

Just the skirts and spoiler to fit now.
Nick

[millworm]

Sweet, window trims smarten it right up

[totalnova]

Wish it would stop raining so I can get out and drive the bloody thing

[millworm]

Same here mate, not driven my fiesta prorperly once this year since i got it out of storage