Project Hungovernova [KET]

[TOZNOVA81]

Bought Balley's old 17TD SX [L393KET] about month or so ago :) and the poor thing is in desperate need of some major TLC!
Here's how KET currently stands before she gets stripped once again for a proper paint job and a major suspension/steering overhaul.
Ive already clocked up 4K miles since I bought her and is not fun to drive at the moment, rattles galore, its like driving a Ford Granada :tard: goes like stink but handles like a bus!

So the plan is to strip her back to her undies.
Complete Rewire
New Doors
New Wings
New Bumpers
New Paint [In & Out]
Install Front Upper & Lower Strut Braces & Front ARB [Why there is no front ARB on it I have no idea?]
Rear Strut Brace
New Suspension all round
Polybush All the suspension, Steering etc
Corsa Epas Column [It needs it!]
Exhaust
Refit the bulkhead sound deadening & install dynamat inside coz its noisy as ****! and probably loads more.....
It certainly wont look "Standard" anymore and hopefully will handle better than bus and be a lot quieter without the rattles ;)


http://photos-d.ak.instagram.com/hphotos-ak-xaf1/10693842_1633700313522955_1775119227_n.jpghttp://photos-c.ak.instagram.com/hphotos-ak-xaf1/10661143_1525091581059866_1313724313_n.jpghttp://photos-a.ak.instagram.com/hphotos-ak-xaf1/10661224_334246410083184_340872281_n.jpghttp://photos-g.ak.instagram.com/hphotos-ak-xaf1/10665466_286630561535686_665085370_n.jpghttp://photos-e.ak.instagram.com/hphotos-ak-xaf1/10666246_344814559027788_1456141047_n.jpg

[jimbob-mcgrew]

strip her back to her undies

^ lol

1.5 D to 1.7 TD was that ? .. must go pretty well :)

if your staying with the rally look, it could use big bugger mud flaps up the front too :cool:

unfortunatly nova's arent the queitest of cars, you might not be able to do a great deal about about the noise, but give it a go, it might help a bit.

does this only get worked on when your hungover by the way ? lol ... or are you always hungover, haha

[Johnny A]

Nice! Considering the weight up front a front ARB should be on the cards... either that or hard front suspension! But without one it may lean a lot but should grip well!

As for making it quiet and refined I can't confirm 100% that using a bucket of sound deadening will cure it. But I am doing the exact same thing, engine bay bulkhead sound deadening, cabin sound deadening (the stuff under the carpet that goes up the bulkhead) and finally a ton of the tar-style sound deadening. I am not using Dynamat but a local company to me, having had a lengthy conversion with them and seeing an example of a Mk2 Golf fitted with their stuff I think it will work wonders. Not only does the stuff kill the sound but drastically reduce rattling!!
I bought one of their full-car kits, I took just one of the 1x1ft tiles and slapped it onto the boot floor of my running XE Nova and went for a drive - with just one tile the exhaust noise from the boot was noticabily reduced! I can't wait to see what 42 tiles will do!

Also EPAS will be a massive improvement in refinement and drivability - both my Novas are fitted with Corsa-B columns.

[TOZNOVA81]

Jimbob She certainly does go well :thumb: haha nah I've ditched those mudflaps now for genuine GM ones all round. Hungovernova is something my gf came up with ;)

Johnny Ye there's so much oversteer its scary atm, the front grips like glue but the body roll is ridiculous. Ye the noise I cant stand, its driving me insane, its got solid engine mounts too which dont help at all with rattling the poor thing to bits haha so lots of soundproofing is a must.
I decided against the epas column and instead fitted a Corsa GSi rack and Saxo epas pump.

Did a bit over the weekend, modifying & installing the pas rack...

First I had to remove the inner track rods from the GSi rack and shorten them by an inch on each as the corsa has a wider wheelbase & re-thread them

http://photos-h.ak.instagram.com/hphotos-ak-xfa1/10707239_455549391249871_1788771805_n.jpg

http://photos-d.ak.instagram.com/hphotos-ak-xfa1/10706657_824249174272323_1812520450_n.jpg

Removed the old rack and laid them side by side to check they were now equal lengths

http://photos-g.ak.instagram.com/hphotos-ak-xpa1/10542010_513647345438974_72258854_n.jpg

http://photos-h.ak.instagram.com/hphotos-ak-xap1/923811_755640984507287_1409118633_n.jpg

Old rack out, not much room with the engine still in there :O

http://photos-e.ak.instagram.com/hphotos-ak-xaf1/10727398_382852388532588_92363474_n.jpg

Then figure out how much bigger I needed to make the hole in the bulkhead for the valve on the PAS rack to fit.

http://photos-d.ak.instagram.com/hphotos-ak-xaf1/10723738_1487843438168403_1033032121_n.jpg

That should do it :P

http://photos-a.ak.instagram.com/hphotos-ak-xaf1/10707246_1487216751530216_1838856150_n.jpg

It fits :thumb:

http://photos-c.ak.instagram.com/hphotos-ak-xpa1/923788_455353304602522_693550442_n.jpg

Connected up to the standard nova column, I will tidy up the hole at some point.

http://photos-c.ak.instagram.com/hphotos-ak-xfa1/10724786_908711635808978_1404024616_n.jpg

The GSi bracket was an absolute **** to fit, ended up having to drop the rear gearbox mount & gear linkage off to squeeze it on, even then it was close.

[TOZNOVA81]

http://photos-h.ak.instagram.com/hphotos-ak-xaf1/10727536_635996406517863_117256813_n.jpg
Rack pipes bolted on all snug :)
Just waiting for my local hydraulics place to make up my new hi pressure pipe then I shall be installing the pump :thumb:

[Johnny A]

Nice progress, but why hydraulic over EPAS?

[TOZNOVA81]

Nice progress, but why hydraulic over EPAS?

Had the PAS rack just laying around collecting dust in the back of the garage, so thought sod it I'll use it :thumb:

[Johnny A]

Fair play, will be interesting to hear your findings compared to EPAS

[craig green]

Hydraulic PAS or EPAS. Both a fair bit of fiddling to install. I had the hydraulic setup on my GSi, found it great apart from the whine of the pump.

Not sure if you have ordered your hoses yet, but I got ripped off by my local hydraulic hose specialist & got urged to use incredibly over specced piping. It was so stiff it was impossible to mount. After discarding it I ended up sourcing some far more suitable hose for a fraction of the cost.

[Johnny A]

I have never driven a Nova with hydraulic pas. I'd like to do a back to back comparison at a meet or something in the future

[Balley]

I will be watching this, keep up the good work.

Ps, never liked the front arb set up, it handled well on Billy's but I kept them on my loon, plus the arms etc are all polybushed. I hope you have plenty of enjoyment out of her.

[TOZNOVA81]

I will be watching this, keep up the good work.

Ps, never liked the front arb set up, it handled well on Billy's but I kept them on my loon, plus the arms etc are all polybushed. I hope you have plenty of enjoyment out of her.

Cheers Dan, ye with all that weight on the front it needs an arb, I noticed today some cracking on the front crossmember where the tie rods bolt on so gonna cut the old one out and fabricate a custom one out of box section as well, She's been trying to tear herself apart by the looks of it.

[Balley]

Arh really, that's a shame! At least you can do it your self. The original cross member started cracking on me years ago. I thought I had sorted that though.

[TOZNOVA81]

I have never driven a Nova with hydraulic pas. I'd like to do a back to back comparison at a meet or something in the future

For sure mate,
Collected the HP pipe from the hydraulics place today that they modified for me, only charged £40 so very happy with that :) was a bit of a fiddle getting the unions done up on the rack but got there in the end and it fits perfect.
Made the bracket for the pump by heating up and bending 2 x 16" lengths of threaded rod into basically massive U bolts which will be bolted to the bulkhead infront of the Heater motor [Only place it would fit], then found some old rubber fuel pipe to insert the U bolts into.
Quickly wired it up to the battery just to test it's all working before I start stripping the dash out to wire it all up and Fcuk me does it make a difference! can steer it with 1 finger now :thumb:
Went for a spin round the block and hasn't had any effect on the steering at speed so I'm guessing the PAS pumps on saxo's/Pug 106's are load sensitive and don't use speed sensors. Winner!
Will get pics and vid up over the weekend.

[TOZNOVA81]

2 Brackets for the PAS pump made from 16" threaded rod & rubber fuel line


http://photos-d.ak.instagram.com/hphotos-ak-xaf1/10735203_295555220642515_799875914_n.jpg

Decided to mount the pas pump on the bulkhead behind the inlet manifold [Only place it would fit]


http://photos-h.ak.instagram.com/hphotos-ak-xaf1/10727652_306752946196663_1124530132_n.jpg

more updates and pics over the weekend

[Johnny A]

Damn I thought the pumps were smaller than that!

[TOZNOVA81]

I wasnt really happy with it behind the inlet manifold, it looked sh1t so decided to mount it under the passenger side scuttle panel.
Perfect fit and after drilling 2 holes in the bulkhead for the HP & return pipe the hoses are a lot neater and all the wiring is now hidden :D


http://photos-d.ak.instagram.com/hphotos-ak-xaf1/10724712_598994616889683_741104208_n.jpg


Also theres no fouling of the wiper mech, plenty of room.


VIDEO HERE

http://videos-a-6.ak.instagram.com/hphotos-ak-xaf1/10742352_533292660149126_763459079_n.mp4

[Kev Turbo]

How are you going to fill the reservoir? I was under the impression that it needs to be completely full?

[TOZNOVA81]

How are you going to fill the reservoir? I was under the impression that it needs to be completely full?

The fill mark is only halfway up the neck so just put slightly more fluid in than normal.

[TOZNOVA81]

Been a bit slow on the updates as waiting for parts so have been doing some bodywork & started stripping the inside out ready for soundproofing.
New boot is almost finished, once this goes on there'll be no locks at all so if anyone's got a load of quarter light glass for me just incase the battery goes flat lol
New suspension will be going on over the weekend too


https://scontent-a-lhr.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/1505533_10152885080953023_7326544008661031885_n.jp g?oh=bb90538ad2ee332436bed3e1dffe534b&oe=54E859CF


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[TOZNOVA81]

Started installing all the soundproofing this weekend

https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/10395859_10152905408523023_8655489976209429166_n.j pg?oh=7f998c85e530d939988269f90ee69293&oe=55151FF1

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Also pulled out the PAS pump and stuck some proofing under the scuttle where it lives, has reduced the whine of the pump dramatically.

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/13150_10152905408293023_8594125087796091243_n.jpg? oh=d3ba6734f53bc7bdc4f180fdae21f11f&oe=55178D49&__gda__=1427498777_4ae0695c712c882ea10f4ea1a24d662 2

[millworm]

just need the factory bulkhead and bonnet sound deadening to finish it off haha

[TOZNOVA81]

just need the factory bulkhead and bonnet sound deadening to finish it off haha

Haha indeed, Im going to pikey it out of my other nova i think.

[TOZNOVA81]

Attacked the rear bumper this week as when the new boot goes on need somewhere else for the reg plate, but instead of just screwing it to the bumper I want it to be tidy. So measured up and cut a hole so I can make a fibreglass recess with a LED strip lamp in it.
Also enlarged the cut out for the exhaust for when I send her off for the new stainless system.

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/1377229_10152919531808023_6091468065605025873_n.jp g?oh=76e40d130c26fdb16fac5e1269bc13e4&oe=551919C4&__gda__=1427972526_f8c6aad84a28dfd6afa0c31206f724c 0

Used a bit of the bumper that got cut out to fill and smooth over the old number plate lamp

https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/15468_10152920201518023_2271070139599932555_n.jpg? oh=76d9fc54d9dac887754b2ab35720e1e6&oe=5515D6B6

Will look good I think

https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/1505230_10152920199413023_5065310215721586273_n.jp g?oh=2e7d535a8d3deaaf0d65b4d05c9c2537&oe=551A4B57

[jimbob-mcgrew]

thumbs up for the sound deadining, nova's are bloody awful on the noise front

[Southie]

The bumper is different and I like people trying something different, never really liked flush boots though so looking forward to seeing the rear all together when finished.

[TOZNOVA81]

Decided to utilise the bit of chopped out bumper to make the side bits for the recess. measured and marked up and cut them out.

then shaped them on the grinding wheel.


https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/1391784_10152925804048023_4693365559596392410_n.jp g?oh=fa261fb8580c717d9afa600ebaab7800&oe=5510DBD8

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[TOZNOVA81]

Some progress this week with a few bits.
Finished the fibreglass recess in the bumper, filler primed & ready for paint shop.
Fitted the boot solenoid & the new boot, stuck it on to see how she looks so far.}Getting there slowly but surely :D

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xfp1/v/t1.0-9/10616189_10152936758668023_1100612254017793961_n.j pg?oh=5ed7fb795825907582a0551150428826&oe=551D8127&__gda__=1425665858_88857aa7f6d63ae4227c2a6b6e56e6f 3

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https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/10407181_10152936758678023_3253775753910065695_n.j pg?oh=d184518af3af8521eea1d1fe94c3b90a&oe=54FCAC8A



Before

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AFTER

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/988866_10152951933058023_6465129811229060558_n.jpg ?oh=21662a22564f84f0070b29d87de2c967&oe=54FB843A&__gda__=1428158988_cf62591c28db29c11fe507fa5514604 5

Back in the garage tomorrow for another full day on her

[TOZNOVA81]

More stripping today and more soundproofing.

https://scontent-a-lhr.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/10629638_10152956087728023_594811356116332823_n.jp g?oh=a1c4f86e4f6f96f0e17d96dcf209ac8a&oe=5519C2AD


https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/10404377_10152956087723023_8094100752837448032_n.j pg?oh=436ee4b2b719c084c83a6694766c31bf&oe=5508C351



Also managed to get hold of the factory engine bay firewall soundproofing off ebay today, needs a clean up tho.
Engine will be coming out over xmas and I will be stripping the rest of her & prepping her for a new paint job :D


https://scontent-b-lhr.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/10428714_10152955448543023_7329964785328437824_n.j pg?oh=98b8102255c5409bd3d850461ff882c3&oe=54FE27CF

[TOZNOVA81]

Finished installing all the Silentcoat soundproofing today and my roll of 12mm pu foam underlay arrived :D


https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10389178_10152965090523023_3996445673420294568_n.j pg?oh=e82df568f31367abf0dfc487efe02790&oe=5506C132&__gda__=1425671716_0f229f218e1cc987e6d58c6f4537480 9

First layer in, bit of a ball ache cutting it to match the carpet but got there in the end :thumb:

Think I may have the quietest Nova in the world once this is done lol


https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10847814_10152965090528023_1227766234106797560_n.j pg?oh=bc8bcce74ec4447b8992da14948c518d&oe=554473DA&__gda__=1430508236_16bacb4f10ec67f260671c3e7c06967 c

[Southie]

I think you should get some PNG slippers for what will be a cosy Nova lol

[TOZNOVA81]

I think you should get some PNG slippers for what will be a cosy Nova lol

Haha

Finished the interior soundproofing now finally, only took 49 hours! Here's a few pics.

https://scontent-a-lhr.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/10277762_10152970055153023_8997178487907339463_n.j pg?oh=50d695e55c699c7de4a1a27f136604b7&oe=5513D395



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Glad thats over n done with, really bloody quiet inside now :D.

Can move onto prepping her for paint now.

[TOZNOVA81]

Finished spraying the front bumper today too :D not a bad job too if i say so myself :d

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xap1/v/t1.0-9/1484272_10152971607793023_1329637151790626118_n.jp g?oh=4e71c02d61b55bf6e57abb66f93915d6&oe=54FD7311&__gda__=1426069032_599d3ec748bd0e795ba37a3ac69958a 2

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[BRoadGhost]

I got no idea how in car electrical fires spread so quickly ;(

[TOZNOVA81]

Lol its fire retardant :thumb:

[TOZNOVA81]

Took the clock out and modified it so I could put the Boost gauge in its place..

https://scontent-b-lhr.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/10410672_10152978704578023_8590877367448245714_n.j pg?oh=6430d943bf3f2f7ba941c6a9f7a2ad90&oe=553E6A45

bit of hardboard and som resin.

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xpf1/v/t1.0-9/10360951_10152978704603023_7822399925397116362_n.j pg?oh=2130e1fef81747efe3df5501d4ee8d66&oe=54F95CF6&__gda__=1426065033_88989a1007354fd55b9feb60b799571 0

Some filler...

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Some fibreglass...

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Test fit...

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Some paint....

https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/10300012_10152981222158023_5678862809881406292_n.j pg?oh=d301842bdafe6175bf3b049b33561f4c&oe=55406D0E

Fitted nice and snug..

https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/10846456_10152981222148023_2849397587431425532_n.j pg?oh=5c5134c8264b32e826525fb08358404e&oe=5504F34E

Looking good :D

https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/10857879_10152981222153023_2951290844676441634_n.j pg?oh=f867d47883f3d6d0c6fc3375d857795f&oe=5537FFAB

Now I just have to sort the rest of the dials out to match lol

https://scontent-b-lhr.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/10689596_10152981222168023_6641946532133957985_n.j pg?oh=4bf467b69c7a4c750bf1f37a4dffbd33&oe=553A82AB

[TOZNOVA81]

Front end & back end finished


https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10500389_10152983545443023_7381078066621709715_n.j pg?oh=8a3fde10c015e724d4a1a86bc38ccba5&oe=553CFEBB&__gda__=1430559405_4807b6e988c2ed6965cccb5d8cec01c 9

https://scontent-a-lhr.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/1395351_10152983545438023_1385462469611470871_n.jp g?oh=b8cc1f62120b3d1732e6b46ceed3e9dd&oe=55410FC9

[TOZNOVA81]

Got Ket some new shoes but can't decide on whether to keep the wheels white or paint them matt black like the bumpers...
Maybe once the matt black skirts go on it will become clear what to do..

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10731005_10152994221773023_1065768516772861350_n.j pg?oh=f13aa0737942e7524bb57cdfbb2ab517&oe=55305894&__gda__=1428319362_0a392043fb8a6c59e7077b51a9ac892 3

https://scontent-b-lhr.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/10686771_10152994221793023_5323951873504496481_n.j pg?oh=eaaf49ebf30ff38550b18c42e94eac97&oe=5526DBC8

[NovalutionGSi]

Looks good on the White rims I think. although the only thing I would personally ditch is the sun strip.

[TOZNOVA81]

Sunstrip is gone now :thumb:

Shall be removing and butchering the manifold on the weekend and spin the turbo round 180deg, so the exhaust is on the gearbox side and I can get rid of the stupid pipe going over the top of it.
Should make a bit more space up front and reduce the amount of heat that pours out of the front of this thing. also be able to get the new exhaust made after I've spun the turbo round as at the moment there's about and inch of space between the flange and the alternator, no room for big bore pipe :roll:

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpf1/v/t1.0-9/10533828_10152652170403023_6804525297878852008_n.j pg?oh=210b5253add87bb23aca1754d97553bd&oe=552BCDB3&__gda__=1433274316_069ce1ed1e4f53d26a75ffed7680f1c c

[TOZNOVA81]

Been pottering about with bits here n there, excuse the sh1t pics.
flange cut off the manifold ready to be repositioned

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10417766_10153091059893023_4228122128785533519_n.j pg?oh=18d6eddc0a2c63d8edb9d8fd8833b7c6&oe=558944A0&__gda__=1434409142_cfcf2488593d93857ee872163cacd48 a

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10940590_10153093783548023_3183263073646362913_n.j pg?oh=04aeb876a98bac693f997eed400d1e7b&oe=554E0242&__gda__=1434978388_4f98b6322a864f413e80738fa2371bb 6

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-xpf1/v/t1.0-9/10929014_10153093783543023_7343731084351745917_n.j pg?oh=049ccc872d8acb51f1e0302a9b5d370d&oe=55856BCC&__gda__=1434552243_d0c0d6fe0a0822993993fa7e44319e3 6

Had to chop an inch off the intake on the turbo for clearance to fit the silicone hose on, going to have to grind off the heat shield lug at some point too.

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10421975_10153178562158023_5094404528665725356_n.j pg?oh=4408c55cd775a6dd00e2851b2cc3fcda&oe=559474D0&__gda__=1434213318_e9bfb9b8e1675947d37639e8305ec80 b


Plenty of room for the exhaust now to go where it was meant to

https://scontent-lhr.xx.fbcdn.net/hphotos-xaf1/v/t1.0-9/11025792_10153178562153023_6490616660729198500_n.j pg?oh=4b758124b545304545564bdd17522334&oe=5583E023

https://scontent-lhr.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/10407904_10153178562138023_7774595599801936444_n.j pg?oh=472ba4acbdb91617d9138dadd920e193&oe=55860754


Decided to refurb the wheels myself instead of having them powder coated, they were in a bit of a sorry state, lots of bad curbing and deep gouges.
cleaned all the damaged bits off and filled with liquid metal sanded and then sealed.


https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10888682_10153004430358023_2991845023332055824_n.j pg?oh=1c53468a11d759875f1709a4f8d8d6f8&oe=558397A0&__gda__=1435147446_98d1d33fca1064902ca7cbdc6af71e4 2

https://scontent-lhr.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/10384934_10153004430348023_4107358468115144170_n.j pg?oh=90cc2ceec9db9b8c040a58afc38dd3c3&oe=55857A82


https://scontent-lhr.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/10897122_10153004430843023_8098425679145247556_n.j pg?oh=ab47bfee29d8a6e776e88e8e1af1e7f9&oe=5586EBE1

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xfp1/v/t1.0-9/10409113_10153004430838023_8613050697588873003_n.j pg?oh=434dfd6cc4cda5950f8efbdafe2c6c39&oe=558BAF64&__gda__=1434236929_a861cbb0234da5deb2d2a664d0072bd 8

Repaired

https://scontent-lhr.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/11015066_10153178562333023_460647374697545887_n.jp g?oh=747650e94d60d103e8c9886ab0f29519&oe=55910B67

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/1012945_10153004430848023_8786533711496265879_n.jp g?oh=791bd9fe936e52e26a7f87c931956dba&oe=558EB482&__gda__=1434372328_6a8e02bde8e6f9a81479e4dd11686a8 c


https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/10888355_10153004430818023_2987280453425603950_n.j pg?oh=3f3d85d9595d7e5b676cc61a36ce4e53&oe=557DFE86&__gda__=1435535467_b95197c450a6ce4f69f83fb71edd180 2

After 2 litres of gloss white and some lacquer they all look brand new again, did the center caps too and bought new griffin badges.

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xaf1/v/t1.0-9/10847805_10153144457008023_1113021720499684412_n.j pg?oh=99457d3a75900e18f672abda51a37978&oe=559312FD&__gda__=1435779913_bc2a3e7fd32d10092ee41896c6bf08c f

https://scontent-lhr.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/11022569_10153178562338023_1787176597781549523_n.j pg?oh=86bf24c59bac78cb4c6b4bdab1f96689&oe=557ADA8C

[TOZNOVA81]

After seeing on Benn's build thread the difference the sm led side lights made, I went and invested in new bulbs for the whole car :thumb:
13 Sm LED sidelight bulb on the left. Normal 501 on the right.

https://scontent-lhr.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/10433117_10153069028003023_3179741039835622584_n.j pg?oh=6da41bdddd06e8047be8e86dc139a33f&oe=558A94B4

Cordoba Splitter

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xfp1/v/t1.0-9/10471341_10153178562143023_9077439083847492650_n.j pg?oh=19d5a06f459920a6499994b510b63108&oe=557A0D2F&__gda__=1435460170_777cef6286e04e77bb2a4e85984686d 8

[TOZNOVA81]

Bits of box section turned up today so started marking & measuring up, still waiting for the 16mm cds tube to make the crush tubes out of tho.

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xfp1/v/t1.0-9/10347497_10153232852453023_7009098314143077640_n.j pg?oh=11699a8e0d65c5d1ee089c74212813e1&oe=5578A099&__gda__=1438486524_0d8f5faa6be5f1ae70d3e6ee88447ed 9

[DAVIDKEDENS]

Enjoyed the read, keep up the progress chief !

[Scottcooper85]

Making good progress here pal.

[TOZNOVA81]

Cheers guy's :)
Yep making progress for sure Scott slowly :thumb:


Little bit of an update..
Well here is the old rather rotten and patched up crossmember chopped off.

https://scontent-lhr.xx.fbcdn.net/hphotos-xtp1/v/t1.0-9/10308393_10153244679358023_5428137820520454448_n.j pg?oh=ae1b374f11909b430d591a585c3d461e&oe=559D6E3C

Ket minus her front.....

https://scontent-lhr.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/11084285_10153244679368023_7306367784778260632_n.j pg?oh=479b081d2bb36e035719321a42617c68&oe=559EB5D1




Almost finished the new crossmember now, been fitting the crush tubes for the tie bars, awaiting a bit more box section and then will hopefully have it all welded back on this weekend :D


https://scontent-lhr.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/11025744_10153253134768023_2435312522915995866_n.j pg?oh=b1cd799f309f725fd97062163a4f094b&oe=5570EE7A

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xap1/v/t1.0-9/149350_10153253134783023_4937851571689668741_n.jpg ?oh=4907eda9823d3e48c375aa54677a5c24&oe=55A6A1FB&__gda__=1437517095_ef3f57d0e27f0805c034dc94eccbb8f 8

Bolted the crossmember on just to check all my measurements were correct and everything lined up correctly, so far so good :thumb:.

Will be lowering it 25mm from its original position tho as the gearbox rubs the tie bars, partly the reason I decided to fabricate my own custom x-member in the first place.

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/11096472_10153253134808023_5374974784874319660_n.j pg?oh=46e93b44e15d2758f9e01a2e5fe282bc&oe=559E0CC5&__gda__=1437653203_a64eb8afcf9055a89832d09ecb3c236 8

[TOZNOVA81]

Strengthened up the chassis legs and got the the crossmember tacked on but thats as far as I got.
I ran out of argon and also managed to get 7 shards of mild steel in my eyeball :/ so its kinda put a stop to anymore work till my eye is fully recovered.

https://scontent-lhr.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/11138116_10153260076743023_3123284315859088116_n.j pg?oh=3a5e6a37e54db0176bbd4a92bbf13853&oe=55DEF49A


Just got to finish plating up the insides & outsides of the chassis legs and box the box section in. tidy some of the welds off and go at the crossmember on full power with the welder :thumb:


https://scontent-lhr.xx.fbcdn.net/hphotos-xpt1/v/t1.0-9/11050822_10153260076748023_1843010989296227973_n.j pg?oh=711a67185b10922283ff270f9171a8ec&oe=55DD985D

[nova_niek]

Nice project, I'm interested in how quiet (if not silent) the car is with all the insulation you've put in there. Love diesels!

[TOZNOVA81]

Nice project, I'm interested in how quiet (of not silent) the car is with all the insulation you've put in there. Love diesels!

Thanks mate, not finished the soundproofing yet tho, still have her **** end to do [Back seats, Roof, Boot floor & in the doors and back panels] but what I've done so far just on the front end has made a massive difference, still got the GM bulkhead deadening to go on too when the engine comes out in a few weeks, sure that will help loads too.
Dunno why it wasn't put back on tbh?
I know she'll never be as quiet as a new Audi but I'm gonna try haha.

[TOZNOVA81]

Bought some new arms, made some plates out of 2mm steel and welded the fcukers on :D

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/11175004_10153322129073023_4778696458261012605_n.j pg?oh=ce112394b0bce22665a65677caa7ca49&oe=55C755E6&__gda__=1439839472_c49d34b3c391db1522991c7bf5cbf3c 5

https://scontent-lhr.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/11178267_10153324013238023_986188137597128408_n.jp g?oh=e786ad97e45bb1b91ea4f5eabf5ca4cd&oe=55DEC7DE

[TOZNOVA81]

Little update, been ripping the headrests apart and unpicking all the stitching to make the patterns so I can make leather headrests.
Bought a sh1t load of black & white leather to make new headlining with, new doorcards with speaker pods and of course to recover the seats.


http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/2015-05-25%2013.23.05_zpsworiejgc.jpg

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/2015-05-25%2013.23.13_zpsqgck3es8.jpg

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/65705053-3a7f-4e82-9017-7c00c0c5c03a_zpsvy0kktie.jpg

New Doorcard backing 4mm mdf

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/2015-05-18%2015.33.28_zpsto2jfmyg.jpg

Pods to go on

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/2015-05-18%2009.18.35_zpsl9esl09w.jpg

[TOZNOVA81]

Have been looking at the horrendous white/cream plastic trim on the A/B & C pillars wondering what I could do to make them not so shit.
I was going to paint them all but in time paint will scratch and eventually look shit!
So as I'm re-trimming the headlining in black leather I thought fuck it i'll do these too :)
Will be doing the parcel shelf supports also, should help reduce rattles and creaky plastic type noises too.

Left covered in leather, Right ghey cream plastic

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/2015-08-05%2019.31.43_zpsp74arajl.jpg

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/2015-08-05%2020.26.02_zpscteeb8mu.jpg

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/2015-08-05%2017.12.18_zpsuc2xxnru.jpg




These next....

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/2015-08-05%2020.26.49_zpsfxs0lfgg.jpg

[totalnova]

Looks good I'm interested how your going to re trim around the speaker holes.

[TOZNOVA81]

Looks good I'm interested how your going to re trim around the speaker holes.

I'm just covering over them, there's no speakers on them anyway.

[TOZNOVA81]

B pillars done and top part of boot panels :)


http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/2015-08-06%2022.57.50_zpsozl77sra.jpg

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/2015-08-06%2022.58.09_zpsofhlzqfo.jpg

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/2015-08-06%2023.18.28_zpspdnflfbm.jpg

[TOZNOVA81]

Stripped all the shitty headlining out to make the new leather one..

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/8777BFFD-3B34-4C51-84D9-8DF869843337_zps0wvygruj.jpg

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/D3DF8C0C-1D6E-424C-9213-606E0D45ACA1_zps3byspjew.jpg

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/861BA31F-BF76-48AA-8B8A-74A7F09E051D_zpsihqxkqzh.jpghttp://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/7281D4C6-CF51-4AF3-B4F5-1082B2BEFF6C_zps8iaz2izi.jpg

[brainsnova]

Nice job on the retriming

[ben doodar]

Trimming looks nice. Been thinking of doing mine in grey leather to match the dash etc. look forward to seeing more.

[nova_niek]

Nice indeed!

[TOZNOVA81]

Boot panels nearly finished.

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/2015-08-12%2020.52.17_zpss8bsrfck.jpg

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/2015-08-12%2020.51.53_zpsdleguuja.jpg

[TOZNOVA81]

Doorpods being retrimmed


http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/DAB1509D-0F58-4DAF-935D-D4A0C4E9A7F5_zpscfghhzfs.jpg

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/E75AC893-5C57-4EA1-9E6F-1F4186FCC0A6_zpsp6dofewd.jpg

Just got the Dashboard to do and front and rear door cards to make now and I can start throwing the interior all back together

[TOZNOVA81]

Been a while since I updated this so here goes...
Interior still isnt in yet as theres a few more bits to finish, I've also decided to paint the car Laser blue, bored of the white plus the rear end soots up so quickly it being a boosted diesel and it looks shit and I really cant be fucked washing the bloddy thing everyday lol.
Anyway I'll let the pictures do the talking.....

Custom black leather headlining

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/7F0C2CC7-C943-4D30-9BBF-AC1940487C17_zps05t9vzr0.jpg

I wet n dry'd the mouldings off the light clusters till they were smooth and then half tinted them then gave them a nice coat of lacquer.

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/2015-10-16%2013.24.37_zpsb5bxdo7v.jpg

crossmember finished and lowered 1.5 inches for clearance from the gearbox all painted and stonechipped.

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/2015-10-31%2015.41.26_zps4kktovqx.jpg


Had to make some new brackets for the Alloy rad so the FMIC would fit nice n snug.

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/2015-12-06%2017.18.12_zpsouudi808.jpg


http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/4F2F1B5F-1F4F-4129-B83E-493ADA978815_zpsez6zb4d7.jpg

Test fitting the cooler and rad, I also attacked the inlet manifold and rocker cover to some nice high temp enamel, I have a million new blue silicone hoses to replace the stock GM water hoses etc.
bought blue cable ties and cable wrap too, you could say I've gone a bit overboard with the blue bits but once its all together it will all look good I hope.

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/3A73EFC2-8347-492E-9194-FEF0B5C0C449_zps0zsm9omr.jpg

Mint new dash getting prepped for some paint, flexi plastic bumper paint then holographic metal flake in the lacquer
ended up looking like this....

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/ABB31686-D910-4650-B604-B98AF54315BC_zpsihedwadc.jpg

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/A115CCC0-1884-4149-B3F1-C63F26364696_zpssyei9vzo.jpg

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/4D5681A1-86CC-4F1D-9D2D-191A4744E974_zpsy55fswdd.jpg

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/C33CEF11-BB30-4FCB-B56C-CE0B4BB310A8_zpsfe8c2kd8.jpg

Quite pleased with how it turned out :D

[BRoadGhost]

All nice & reflective so it can constantly annoy when driving!

[TOZNOVA81]

All nice & reflective so it can constantly annoy when driving!

Its actually not that bad tbh mate

[jimbob-mcgrew]

size of that intercooler ! lol

[TOZNOVA81]

Haha I know, I had a hell of a job hiding it behind the bumper :O

[Plug]

It's a mk2 you've got miles of room, I hid one of similar size behind a mk1 bumper now that was tricky, can see the curve in the bumper where it stretches over the intercooler lol

[TOZNOVA81]

New paint for wheels, bumpers and skirts :D

http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/2016-04-01%2016.43.50_zpsk8l5lhsh.jpg


And some nice new aqua blue pearl for the respray, sick of white, fucking boring colour lol.


http://i1167.photobucket.com/albums/q633/TozNovaGsi/L393KET%20Hungovernova%20Turbo/Kets%20new%20colour_zps7rulvb1u.jpg

[nova_niek]

Shiny as!