Mk1 Black Saloon

[ABoresta]

Now I am finally a club member I thought I would start a project build, I am missing so many photos from when I first bought the car but I am trying to gather them all and try to fill in the gaps, but in the mean time here is a spec list and current photo of the my car :)

The Car
Mk1 Vauxhall Nova 4 door Saloon –1987
46,500 miles

It was a drunken night at university i placed a bid on the bay for the car and got an email the next day saying I won it :)
And then it all began and the work below was carried out.


Exterior
SR front bumper & grille
Mk2 rear bumper
Cesaros (& spare)
Bonnet lifters
Aero catches
Front & Rear tow strap (Red TRS)
Custom Boot Vinyl (SR style)
Removed sunroof, Aluminium plated and riveted


Interior
Fully Stripped
Bucket Seats – Cobra Monaco S
4 Point Harness (Red TRS Cobra)
Mk1 Dash with - Custom Gauge plate –oil pressure, oil temp & water temp
6 dial clocks
Misc switches
SR steering wheel
Corsa internal shifter
Custom door cards & grab handles
Shift light


Chassis
288mm Front Brakes
240mm Rear Brakes (Corsa C Sri) with braided brake lines internally run with brake bias valve
Adjustable coilovers all round
6 point roll cage with door boors etc
Front and Rear strut brace
Secondary RARB
Fully Poly Bushed
Strengthened lower arms
Cut back chassis leg
Full Harry Hockly Chassis strengthening kit
Engine bay seam welded

Mechanical
C20XE – 1991 (I think) Cavalier Gsi 75,000miles
Adjustable fuel pressure regulator
F20 gearbox with corsa gear selector
GTE drive shafts with mk2 cav inners
GTE radiator with 12” slim line fan
Rose jointed gear linkage
Corsa B multi point injection fuel tank
Fully braided fuel lines internally run
2 1/4” Powerflo exhaust with 2 1/2”out rolled tip
Battery re-location to boot with master cut off & pull cord
Polyurethane engine mounts
Omex rev limiter and launch control
ZX9R Bike carb conversion with H&H ignition


http://i252.photobucket.com/albums/hh23/alexb1234/9b80cc0e0e402f195df86ddb3ce67888.jpg (http://s252.photobucket.com/user/alexb1234/media/9b80cc0e0e402f195df86ddb3ce67888.jpg.html)


To do list

Exterior
Gsi sideskirts(sprayed Graphite Grey)
Full respray car and wheels

Interior
Plumbed in fire extinguisher
Move drivers seat (make adjustable)
Flocked dash
Suede steering wheel
Driver and passenger footrests

Mechanical
Re-locate fusebox and washer bottle

[burgo]

Very smart car that

[House]

What's the wheel colour dude? I'm looking to get my cesaros a similar gun metal grey!!

Tidy looking motor!!

[ABoresta]

What's the wheel colour dude? I'm looking to get my cesaros a similar gun metal grey!!

Tidy looking motor!!

Cheers guys
The wheels i did with rattle cans from halfords for now until i get them powder coated it is a wheel spray I cant remember the exact colour but I will find out tonight and let you know.

[ABoresta]

The first picture I could find was with the engine already out, and the interior fully stripped with the seat frames welded in, internal shifter in place as a mock up and a quick coat of hamerite throughout the car.
When I bought the car the wings and doors had all been smashed in, rear quarter glass was smashed and head was blown on the original 1.2 engine.
http://i252.photobucket.com/albums/hh23/alexb1234/0cd8b954-562b-41c9-980d-65cbb3b72644.png (http://s252.photobucket.com/user/alexb1234/media/0cd8b954-562b-41c9-980d-65cbb3b72644.png.html)
http://i252.photobucket.com/albums/hh23/alexb1234/e65671e5-c85a-48d0-ac41-51083114e60f.png (http://s252.photobucket.com/user/alexb1234/media/e65671e5-c85a-48d0-ac41-51083114e60f.png.html)
I lowered and pulled the passenger seat back as far as I could to try and lower the centre of gravity and improve weight distribution when I have a passenger.

As I was at uni when I started the project most parts were found on the internet at low prices which saw these Cobra Monaco S bucket seats with TRS Red 4 point harnesses £100 for the lot which I thought was a bargain! So these got test fitted to the car.
http://i252.photobucket.com/albums/hh23/alexb1234/847b877c-5edf-4dd0-a685-54fe6ce8a88d.png (http://s252.photobucket.com/user/alexb1234/media/847b877c-5edf-4dd0-a685-54fe6ce8a88d.png.html)

Next to address was the leaky sunroof,I took the original unit out completely and realised how heavy it was and decided to replace it with a sheet of aluminium and rivet it to the roof, no more leaks and weight saving.
http://i252.photobucket.com/albums/hh23/alexb1234/3C56C0AF-AF23-41EC-ACC1-2B22BFF50C5B.jpg (http://s252.photobucket.com/user/alexb1234/media/3C56C0AF-AF23-41EC-ACC1-2B22BFF50C5B.jpg.html)

Whilst at university I made use of the workshop and equipment there so I designed on my roll cage on CAD and made a 3D copy of it in 1/10th scale on the rapid prototyper (picture to come) the design was sent to safetydevices and as part of the project got some great help and the bars with bends were provided for a great price so all was left was welding it in and fabricating the straights and extra bars I wanted.
http://i252.photobucket.com/albums/hh23/alexb1234/2e1ed27d-cf9a-456e-b634-f3c8d83e4986.png (http://s252.photobucket.com/user/alexb1234/media/2e1ed27d-cf9a-456e-b634-f3c8d83e4986.png.html)

I picked up a grey mk1 dash and SR steering wheel at VBOA so that was fitted along with the 6 dial clocks I picked up as I wanted the tacho.
I also had access to a laser printer at that time and made up a gauge plate for 3 gauges situated where the original stereo was as the car didn’t come with one anyway. Its just black acrylic and I put a little Vauxhall logo in the corner,simple, does the job and im pleased how it looks.
http://i252.photobucket.com/albums/hh23/alexb1234/c6dce294-3777-47f7-aeeb-c62126003f81.png (http://s252.photobucket.com/user/alexb1234/media/c6dce294-3777-47f7-aeeb-c62126003f81.png.html)
http://i252.photobucket.com/albums/hh23/alexb1234/66b24d04-2caf-4e61-98e7-578c943d90bd.png (http://s252.photobucket.com/user/alexb1234/media/66b24d04-2caf-4e61-98e7-578c943d90bd.png.html)
http://i252.photobucket.com/albums/hh23/alexb1234/db029313-0941-4678-b152-8abf4644c07c.png (http://s252.photobucket.com/user/alexb1234/media/db029313-0941-4678-b152-8abf4644c07c.png.html)

While I still had use of the ramp at uni I test fitted the engine I got from someone on migweb it was a very clean decent mileage engine at a decent price, so first job was to see where I had to cut back the chassis leg and I tig welded in some plates.
http://i252.photobucket.com/albums/hh23/alexb1234/e8ccff7b-2172-4b59-9623-d25215ad47cb.png (http://s252.photobucket.com/user/alexb1234/media/e8ccff7b-2172-4b59-9623-d25215ad47cb.png.html)
http://i252.photobucket.com/albums/hh23/alexb1234/cf18d2cd-1031-41e9-82ff-14ee42eb5bcb.png (http://s252.photobucket.com/user/alexb1234/media/cf18d2cd-1031-41e9-82ff-14ee42eb5bcb.png.html)
http://i252.photobucket.com/albums/hh23/alexb1234/9a0cdc5c-203e-4773-840f-e88f49da3c8b.png (http://s252.photobucket.com/user/alexb1234/media/9a0cdc5c-203e-4773-840f-e88f49da3c8b.png.html)

The gsi rad and slim line fan was next to be fitted, mounted it on the front of the rad as it is very tight in the back between the rad manifold and I think looks cooooool. Another little project I made use of the how to guides on here and made a rose jointed linkage, could do with a clean and paint but its all fitted and working.
http://i252.photobucket.com/albums/hh23/alexb1234/9fb20449-be20-4d32-b450-e7ce235876a5.png (http://s252.photobucket.com/user/alexb1234/media/9fb20449-be20-4d32-b450-e7ce235876a5.png.html)
http://i252.photobucket.com/albums/hh23/alexb1234/be05c2d0-44ed-44f0-97cf-9e98ae205aac.png (http://s252.photobucket.com/user/alexb1234/media/be05c2d0-44ed-44f0-97cf-9e98ae205aac.png.html)

First time driving it with the new engine back to the uni house and this is how shes sitting at the moment, with 256mm front brakes, bonnet lifters and bonnet pins, original bumpers and grille.
http://i252.photobucket.com/albums/hh23/alexb1234/b9dac041-0126-417d-88ca-03cfcd0fd7cd.png (http://s252.photobucket.com/user/alexb1234/media/b9dac041-0126-417d-88ca-03cfcd0fd7cd.png.html)

[ABoresta]

I couldn’t decide what colour to paint the roll cage so I just kept it simple and went with silver as I didn’t want to leave raw steel in the car and have to treat that at a later date.
http://i252.photobucket.com/albums/hh23/alexb1234/963ede15-e5b3-450d-a1a8-c06ae970d1a6.png (http://s252.photobucket.com/user/alexb1234/media/963ede15-e5b3-450d-a1a8-c06ae970d1a6.png.html)

Realised I messed up and got mechanical gauges not ones with sensors and senders so I ordered new gauges and my stud conversion bits turned up too.
http://i252.photobucket.com/albums/hh23/alexb1234/8f4ac472-46fd-4532-a7ea-3bc1e3b64ba2.png (http://s252.photobucket.com/user/alexb1234/media/8f4ac472-46fd-4532-a7ea-3bc1e3b64ba2.png.html)
http://i252.photobucket.com/albums/hh23/alexb1234/4c51ca7c-d89a-4367-8e97-6ad6a0565c17.png (http://s252.photobucket.com/user/alexb1234/media/4c51ca7c-d89a-4367-8e97-6ad6a0565c17.png.html)

Got my hands on a SR bumper and grille and a mk2 saloon rear bumper, so they got sprayed up graphite grey and fitted, personally think it makes the car look a lot better.
http://i252.photobucket.com/albums/hh23/alexb1234/a8a01881-5aec-4dc1-907a-82645f54a106.png (http://s252.photobucket.com/user/alexb1234/media/a8a01881-5aec-4dc1-907a-82645f54a106.png.html)
http://i252.photobucket.com/albums/hh23/alexb1234/287a33e0-3a33-48f1-b19c-926043fb5574.png (http://s252.photobucket.com/user/alexb1234/media/287a33e0-3a33-48f1-b19c-926043fb5574.png.html)

Took a trip to Santa Pod for RWYB which was just fun to drive the car tobe honest, didnt run record breaking times but got some good feed back from the car on what I need to work on and change etc. The headlight came out for air flow (not sure if it makes a difference or not)
http://i252.photobucket.com/albums/hh23/alexb1234/0dd82a9a-6f06-47c8-8f23-45b14f3c9776.png (http://s252.photobucket.com/user/alexb1234/media/0dd82a9a-6f06-47c8-8f23-45b14f3c9776.png.html)
http://i252.photobucket.com/albums/hh23/alexb1234/808d5bfb-b775-4b9e-90ac-41fe98046063.png (http://s252.photobucket.com/user/alexb1234/media/808d5bfb-b775-4b9e-90ac-41fe98046063.png.html)
http://i252.photobucket.com/albums/hh23/alexb1234/a407e80d-ad17-4eab-96f2-0c89fcac84d2.png (http://s252.photobucket.com/user/alexb1234/media/a407e80d-ad17-4eab-96f2-0c89fcac84d2.png.html)
http://i252.photobucket.com/albums/hh23/alexb1234/33c3e28a-b798-4bc4-887d-86612118eee0.png (http://s252.photobucket.com/user/alexb1234/media/33c3e28a-b798-4bc4-887d-86612118eee0.png.html)

But on the way home the clutch cable snapped and I didnt have a spare so the lovely AA man took me all the way home (70 miles) after waiting 2 hours for him.
http://i252.photobucket.com/albums/hh23/alexb1234/9bb215c8-ca10-4ff9-869e-a45fa3332d13.png (http://s252.photobucket.com/user/alexb1234/media/9bb215c8-ca10-4ff9-869e-a45fa3332d13.png.html)

[House]

Really like the cage and the alternator cut out looks spot on!!

[ABoresta]

Really like the cage and the alternator cut out looks spot on!!

Iv recently found out the alternator cut out isn't big enough and the corner of the pulley still runs slightly so that has to be addressed before my track time next month.

The wheel paint I used was simoniz wheel steel

[House]

All part of the fun mate!! Had to do the same to mine as it was rubbing the alternator, went to cut it out only to find that whoever had done the mod (previous owner) had simply cut a slice in the chassis leg with a grinder and hammered it in then seam sealed over it!! Nice!!!

[BRoadGhost]

Go hydraulic clutch!

[ABoresta]

All part of the fun mate!! Had to do the same to mine as it was rubbing the alternator, went to cut it out only to find that whoever had done the mod (previous owner) had simply cut a slice in the chassis leg with a grinder and hammered it in then seam sealed over it!! Nice!!!

No way?! That's mad how people can think that's a good enough and acceptable way of doing it :S

[ABoresta]

Go hydraulic clutch!
I have been thinking of what to do since my clutch cable snapped, im always nervous when in traffic lol. is there any guides or anything?

[ABoresta]

I ordered a custom SR style boot vinyl for the saloon, as it was annoying me the badges had lost their chrome and cost a fortune for new ones so tried to think of something a bit different...
Im really happy with it what do you all think?
http://i252.photobucket.com/albums/hh23/alexb1234/31201bd8-24fa-4c8c-9e7c-a8f845ab8010.png (http://s252.photobucket.com/user/alexb1234/media/31201bd8-24fa-4c8c-9e7c-a8f845ab8010.png.html)

I got hold of a a Corsa C SRi rear beam with the brakes for a veryyyyyy good price online, stripped the brakes off and weighed in the beam
http://i252.photobucket.com/albums/hh23/alexb1234/2b0db5ce-674b-4b64-8c61-a41b68342d78.png (http://s252.photobucket.com/user/alexb1234/media/2b0db5ce-674b-4b64-8c61-a41b68342d78.png.html)

Took the nova ream beam off stripped it down, cleaned it and painted it up ready for the disc conversion and fitting the secondary RARB using the how to guide on here for the parts list :)
http://i252.photobucket.com/albums/hh23/alexb1234/b3180a7c-e059-4b18-96c9-84ddc12bb657.png (http://s252.photobucket.com/user/alexb1234/media/b3180a7c-e059-4b18-96c9-84ddc12bb657.png.html)

http://i252.photobucket.com/albums/hh23/alexb1234/0136b39b-75b6-43e9-a615-460bb95d9b2d.png (http://s252.photobucket.com/user/alexb1234/media/0136b39b-75b6-43e9-a615-460bb95d9b2d.png.html)

Last little update, I got my V6 brakes on the front before replacing all the brake lines for braided and bleeding it all up. They really do stop well and just about fit under cesaros. (they had been in the garage for a while and got a bit of surface rust in this pic but that soon went)

http://i252.photobucket.com/albums/hh23/alexb1234/9068a9fa-fe00-4abe-aae9-fe61a2792b3d.png (http://s252.photobucket.com/user/alexb1234/media/9068a9fa-fe00-4abe-aae9-fe61a2792b3d.png.html)

You can see how close the calliper gets to the rim and also see the stud conversion aswell.

[ABoresta]

Not the best picture but you can see my internal braided fuel lines and brake lines with brake bias valve.

I have a corsa internal shifter i will be changing over soon because i wanted the cut outs and got a few ideas after reading Iains project build with the selector turret so those mods will be done to hopefully help my horrible gear changes between 2nd and 3rd.

http://i252.photobucket.com/albums/hh23/alexb1234/7F39E430-D462-4A9A-820D-04C00BFEC5E3.jpg (http://s252.photobucket.com/user/alexb1234/media/7F39E430-D462-4A9A-820D-04C00BFEC5E3.jpg.html)

[ABoresta]

Made up some door cards last night, nothing fancy, just wanted something simple and clean looking, just have to do the same for the rear when i get my new doors sprayed up and fitted. Probably without the grab handle but i havent decided if im going to fit the window winder and handle to open the door...
http://i252.photobucket.com/albums/hh23/alexb1234/7B916675-829E-41CD-B35F-D1FEB2CAD332.jpg (http://s252.photobucket.com/user/alexb1234/media/7B916675-829E-41CD-B35F-D1FEB2CAD332.jpg.html)

My ECU was just cable tied back to the roll cage so i made a simple bracket just to bolt it up and out of the way, again nothing fancy but it does the job. I really dont like the fuse box in the original place as you can just about see it doesnt fit properly due to the roll cage so that will be relocated to probably the glove box.
http://i252.photobucket.com/albums/hh23/alexb1234/E5D2B96D-D4CF-4977-97EB-9F7547EF1054.jpg (http://s252.photobucket.com/user/alexb1234/media/E5D2B96D-D4CF-4977-97EB-9F7547EF1054.jpg.html)

Im really not happy with how messy my engine bay is currently, so that is the next task on my list, smaller washer bottle relocated to the scuttle panel, a new header tank as the cav one doesnt really fit well at all and looks rubbish i think and then a lot of re-wiring and loom tape haha. Battery re-location is nearly ready just waiting for my FIA master cut off as i ordered the wrong one then that will be finished and updated :)
http://i252.photobucket.com/albums/hh23/alexb1234/20ECBF08-BC48-47FD-851F-69FC34B9219C.jpg (http://s252.photobucket.com/user/alexb1234/media/20ECBF08-BC48-47FD-851F-69FC34B9219C.jpg.html)

[ABoresta]

Right so I had a bit of an accident last night, my brakes locked up in the wet and there was no way out of it but it ended in tears for me! Right before vboa aswell!
Bent chassis leg, front panel all crushed, passenger wing all damaged, sr bumper cracked and bumper reinforcement all bent.
http://i252.photobucket.com/albums/hh23/alexb1234/B3BB0590-996A-4A07-BC29-4FB01DF421D5.jpg (http://s252.photobucket.com/user/alexb1234/media/B3BB0590-996A-4A07-BC29-4FB01DF421D5.jpg.html)
http://i252.photobucket.com/albums/hh23/alexb1234/BF8C7D1F-85B6-4E9A-B690-AAC95CC66971.jpg (http://s252.photobucket.com/user/alexb1234/media/BF8C7D1F-85B6-4E9A-B690-AAC95CC66971.jpg.html)

any help with parts and advice would be very much appreciated as Im meant to be going silverstone soon as well :(

[conza123]

By looks of the pics u may of only squashed the end of the chassis leg, do u have any pics from above

[ABoresta]

I haven't mate I will get some though :) to be honest the rest looks straight just the front, how did you say to pull it out? My mate said tie something to it and tie it to the tree at the end of the drive and put it in reverse lol

[Richy12]

Aww man, such luck. The car looked awesome pre-accident. Hope you get it sorted for billing. Im breaking a mk2 5 door loon if you need any silly bits?

[ABoresta]

Ah yeah I could do with the side repeaters, the hole unit with the bulb holder and wires etc as the clips broke and they won't stay in the wing. And if your willing to split the bumper from the reinforcement bar? She will be back soon at the moment it's not looking like in time for billing though :(

[millworm]

I got a shell yu can cut bits off if you want chassis bits and I'm only in South London. No outer wings or anything tho

[ABoresta]

Ah mate thanks alot! if i need the front of the chassis leg would you be willing to sell that bit? Iv got a new front panel on the way so thats the main bit that could cause me a problem

[millworm]

Come and cut it and it's yours, your lucky as the front pannel and o/s leg are bent

[ABoresta]

You are an absolute legend mate! im gonna give it a little try tonight if no joy i will get in touch if thats ok?

[millworm]

Yeah mate no probs

[ABoresta]

Had a bit if a nightmare week with the old Man being ill and in hospital so tonight was the first night I managed to crack on with sorting out the front end so hers a little update.
First off all stripped down front end ready to remove the front panel, bumpers in the garage ready for some repairs, lights out, wings off, front ARB and tie bars off.
http://i252.photobucket.com/albums/hh23/alexb1234/667237DD-1500-4D85-B78E-ED5EE28C3D29.jpg (http://s252.photobucket.com/user/alexb1234/media/667237DD-1500-4D85-B78E-ED5EE28C3D29.jpg.html)
http://i252.photobucket.com/albums/hh23/alexb1234/9CAA3EB1-6680-4A0E-8092-24914B434AA1.jpg (http://s252.photobucket.com/user/alexb1234/media/9CAA3EB1-6680-4A0E-8092-24914B434AA1.jpg.html)

Rather than removing the manifold etc to get the rad out i chopped the slam panel and thought this is good time to make a removable slam panel on the new front panel so this can be done in the future and I still keep the ID plates aswell.
http://i252.photobucket.com/albums/hh23/alexb1234/83E875A7-7430-4790-BD0B-CC5D8C7FF624.jpg (http://s252.photobucket.com/user/alexb1234/media/83E875A7-7430-4790-BD0B-CC5D8C7FF624.jpg.html)

With the rad out I made a start on finding and drilling out all the spot welds to remove the front panel, this was actually harder than I expected and was taking longer too.
http://i252.photobucket.com/albums/hh23/alexb1234/6583884D-2EF2-4839-899B-DBC2A6BD3828.jpg (http://s252.photobucket.com/user/alexb1234/media/6583884D-2EF2-4839-899B-DBC2A6BD3828.jpg.html)

And then to top things off the spot weld drill bit snapped :( should have another one coming tomorrow if not there's a screwfix round the corner.
http://i252.photobucket.com/albums/hh23/alexb1234/A6ED83AB-8078-4C71-B12D-3081AB98DA2D.jpg (http://s252.photobucket.com/user/alexb1234/media/A6ED83AB-8078-4C71-B12D-3081AB98DA2D.jpg.html)

So didn't get as much done as I wanted progress was slow but it's a start! Crack on tomorrow and hopefully il have the old panel off straighten the front of the leg and weld the new panel on :)
checked my parts box and found a passenger side indicator which smashed so that was a good find! Although they aren't matching. Also thought of a few things I could do while everything is off the car that I'v been planning but they will be in the next update.

[millworm]

Got some other bits here if you need anything mate, machine mart spot weld bits are the one

[ABoresta]

Or really? I just had one arrive this morning so try again this afternoon if not il get onto machine mart and give you a shout cheers mate :)

[millworm]

Cool, just tap the centre with a punch and it centres in and cuts it all out

[ABoresta]

So the progress today went well I think, we took our time and chilled in the sun a lot but was good fun and made me feel like it will be ready for billing!
So little update for you all, started by trying out hearing the chassis leg hammering/levering into position again
http://i252.photobucket.com/albums/hh23/alexb1234/648384B6-C762-470A-AA2A-B8C36748278D.jpg (http://s252.photobucket.com/user/alexb1234/media/648384B6-C762-470A-AA2A-B8C36748278D.jpg.html)

It started to work but it was slow and took a lot of effort so next up was getting my other car involved and the tow strap, wasn't sure how this was going to go but it did the job and straightened out the end of the chassis leg enough, it's not perfect but it's a lot better! Got two straps bolted on the leg through the hole for the bumper bracket and tow rope to the bmw.
http://i252.photobucket.com/albums/hh23/alexb1234/2B35A755-0D84-45FC-9BC6-3FA2E6ED0D04.jpg (http://s252.photobucket.com/user/alexb1234/media/2B35A755-0D84-45FC-9BC6-3FA2E6ED0D04.jpg.html)
http://i252.photobucket.com/albums/hh23/alexb1234/4D3A989F-E56D-4B79-8E07-1B1A62AD8596.jpg (http://s252.photobucket.com/user/alexb1234/media/4D3A989F-E56D-4B79-8E07-1B1A62AD8596.jpg.html)

Now I was happy with how straight the leg was I got on to welding out the spot welds for the cross member (there was a lot more than I thought!) and now the hole front panel has been removed :)
http://i252.photobucket.com/albums/hh23/alexb1234/84117463-C246-4E10-BEE8-AF7CD0774B3D.jpg (http://s252.photobucket.com/user/alexb1234/media/84117463-C246-4E10-BEE8-AF7CD0774B3D.jpg.html)

Next on the to do list was make up some plates that had rusted through so they got fabricated and welded on
http://i252.photobucket.com/albums/hh23/alexb1234/DA4EF033-84B2-4E7B-8D3B-CE4062129C41.jpg (http://s252.photobucket.com/user/alexb1234/media/DA4EF033-84B2-4E7B-8D3B-CE4062129C41.jpg.html)

And on with the new panel :) it fitted a lot better than I expected to be honest for a pattern part with a little persuasion of course but it's all bolted up with the tie bars to check for fitment and tacked on place ready for welding tomorrow
http://i252.photobucket.com/albums/hh23/alexb1234/D6DAACBC-9F74-4554-B069-61A30D7205B9.jpg (http://s252.photobucket.com/user/alexb1234/media/D6DAACBC-9F74-4554-B069-61A30D7205B9.jpg.html)

Whilst letting things cool down I turned my attention to the boot area the spare wheel well had the last bit of sound deadening in so that was knocked out and I have to make up a spare wheel clamp as mine broke, going to give the inside a paint tomorrow too
http://i252.photobucket.com/albums/hh23/alexb1234/B4FB799E-6AB1-4E4D-9CAA-8397B86F7229.jpg (http://s252.photobucket.com/user/alexb1234/media/B4FB799E-6AB1-4E4D-9CAA-8397B86F7229.jpg.html)

[ABoresta]

So plan for tomorrow is early start welding up the front panel, make removable slam panel (still not 100% sure on how to bracket this to keep its strength so will have a little look how it's been done before to get ideas), rad back on, lights back in, anti roll bar is currently getting a bit of paint to match the rear which Im still waiting for the end bushes from autovaux :( so that can be fitted tomorrow and then have a look what can be done for the bumper bar to sort that out :) then try and make it look half decent for billing on Sunday :)

[ABoresta]

Little update I will get more pics later when the rain finally stops but a pic of my car at billing just for now as I was pleased just to get it there. Didn't look the best but mechanically all fine :)

http://i252.photobucket.com/albums/hh23/alexb1234/58FE7CB7-147A-458E-AA88-F0FBF048DF3C.jpg (http://s252.photobucket.com/user/alexb1234/media/58FE7CB7-147A-458E-AA88-F0FBF048DF3C.jpg.html)

http://i252.photobucket.com/albums/hh23/alexb1234/1B965C9C-030E-4D8E-8CAE-3A638DF434AF.jpg (http://s252.photobucket.com/user/alexb1234/media/1B965C9C-030E-4D8E-8CAE-3A638DF434AF.jpg.html)

[ABoresta]

Another little update I haven't got pics of some of the things I have done but thought I would add a couple, so tonight my end bushes came for the secondary rear anti roll bar so I got onto fitting it :) quite pleased with how it looks and feels just need to test drive the car and see what difference it makes now, you can just about see my braided brake lines aswell but I will get better pictures of them :)

http://i252.photobucket.com/albums/hh23/alexb1234/F47A79E1-358B-4B58-970E-37004C0B11EE.jpg (http://s252.photobucket.com/user/alexb1234/media/F47A79E1-358B-4B58-970E-37004C0B11EE.jpg.html)

Then I got onto fitting the battery master cut off now I have got the proper fia one after a chat on here, so i decided to make a plate to match he gauge plate I made to hold the battery switch and will hold the fire extinguisher pull cord when I get round to buying it lol but this is how it looks at the moment

http://i252.photobucket.com/albums/hh23/alexb1234/2888FB1C-B3CD-4309-B607-75121D0312B5.jpg (http://s252.photobucket.com/user/alexb1234/media/2888FB1C-B3CD-4309-B607-75121D0312B5.jpg.html)

and then onto fitting the pull cord I put the fire extinguisher sticker on ready to check for placement. And of course my png sticker in the window too.

http://i252.photobucket.com/albums/hh23/alexb1234/67243E95-6D1E-49ED-8975-39C2B8DAE751.jpg (http://s252.photobucket.com/user/alexb1234/media/67243E95-6D1E-49ED-8975-39C2B8DAE751.jpg.html)

[ABoresta]

Went to Trax yesterday for a track slot, as the nova has never been out, got a few things to work on:
Brakes
Tyres
Better suspension
And confidence in the car to be honest just need to push it a bit harder

I did have a problem my alternator belt flipped inside out and shredded a bit which snagged the crankshaft sensor and fuel pump wire so on the cool down lap my car cut out, but a couple hours chilling in the sun with the trax girls having a chat to some nice people i got it going again ready for the drive home. And heres a few pics:

In assembly waiting to go out
http://i252.photobucket.com/albums/hh23/alexb1234/D5A3BED3-C5DF-46EC-8C01-C3B49CAAAB83.jpg (http://s252.photobucket.com/user/alexb1234/media/D5A3BED3-C5DF-46EC-8C01-C3B49CAAAB83.jpg.html)

Coming into brooklands under safety car (not the best quality havent sorted the rest yet)
http://i252.photobucket.com/albums/hh23/alexb1234/E6B9262D-23AF-4230-88BC-C1DA5255086E.jpg (http://s252.photobucket.com/user/alexb1234/media/E6B9262D-23AF-4230-88BC-C1DA5255086E.jpg.html)

And finally on the way home
http://i252.photobucket.com/albums/hh23/alexb1234/013A812B-C38C-4181-835A-79D6D739F44B.jpg (http://s252.photobucket.com/user/alexb1234/media/013A812B-C38C-4181-835A-79D6D739F44B.jpg.html)

[ABoresta]

Just got back from Cornwall for the week and thought I better try and get the nova done to get an not to get it back on the road asap. So here's a little update.

new tyres arrived while I was away got t1-r's for road use and the odd track session if I get round to it this year. Then next year may think about a set of semi slicks and keep the t1-r's just for the road? Has anyone used them before its my first time with toyo so not sure what to expect...
Oh and though Id throw in a pic of my old tyres after silverstone because I thought it looked cool.
http://i252.photobucket.com/albums/hh23/alexb1234/3CB1D0E4-AE4D-40AC-98BA-561C71240B9D.jpg (http://s252.photobucket.com/user/alexb1234/media/3CB1D0E4-AE4D-40AC-98BA-561C71240B9D.jpg.html)

http://i252.photobucket.com/albums/hh23/alexb1234/3529200D-326A-4F27-91C3-72D3F069E7FC.jpg (http://s252.photobucket.com/user/alexb1234/media/3529200D-326A-4F27-91C3-72D3F069E7FC.jpg.html)

the first on my list to address for the not was the wheel bearing which was a lot easier than I expected to be honest, little during picture and after fitting.
http://i252.photobucket.com/albums/hh23/alexb1234/AA4301D2-B067-4F29-A239-A268B75097CE.jpg (http://s252.photobucket.com/user/alexb1234/media/AA4301D2-B067-4F29-A239-A268B75097CE.jpg.html)

http://i252.photobucket.com/albums/hh23/alexb1234/C89860C3-A6C2-48A7-9041-313DFD15DA38.jpg (http://s252.photobucket.com/user/alexb1234/media/C89860C3-A6C2-48A7-9041-313DFD15DA38.jpg.html)

[millworm]

I run tr1s on my sierra on the fronts and they keep the grip in in the dry bur in the wet they're shocking

[ABoresta]

I run tr1s on my sierra on the fronts and they keep the grip in in the dry bur in the wet they're shocking

Oh really? Hm may have to think of something for the wet weather then.

[ABoresta]

I haven't updated this for a while so just a quick post and I will get some more pics and updates very soon now work has started again.

Harry Hockley sent out my strengthening kit got the 14 plate kit and top mount plates so now to get the engine out and time to do some welding
http://i252.photobucket.com/albums/hh23/alexb1234/083094EB-432A-47CD-8555-3E41D3FE83EA.jpg (http://s252.photobucket.com/user/alexb1234/media/083094EB-432A-47CD-8555-3E41D3FE83EA.jpg.html)

got lots due in the post soon and lots of work to do :)

[Al1exx]

Excellent work mate!

[Iain]

Out of interest how much does the plating kit weigh?

[ABoresta]

A lot less than I thought to be honest but I will weigh it as soon as I get some scales haha

[ABoresta]

Haven't got round to getting some scales to weigh the strengthening kit but I haven't forgotten!

But it a little update, something turned up today which definitely gave me motivation again!

http://i252.photobucket.com/albums/hh23/alexb1234/80B6834F-58A6-48E7-A1DE-7FC178BD132A.jpg (http://s252.photobucket.com/user/alexb1234/media/80B6834F-58A6-48E7-A1DE-7FC178BD132A.jpg.html)

thats right ZX9R bike carbs :)
havent decided what I'm going to do about the manifold yet, I was told it was running on an auto grass car or something?
So will give them a clean up and go from there, but first I will test fit before the engine comes out to check for space and decide what to do about filters and bulkhead etc...

spoke to H&H ignition about a kit they do which I'm looking at and I found a fuel pressure regulator that will allow me to keep the original pump and braided fuel lines I have in place already but will reduce the fuel pressure down to 2psi :) so time to spend some money and get ordering.

Still on the look out for cams!

[ABoresta]

Havent updated this for a while been trying to crack on for PVS so here's what iv been up to.

Chassis strengthening kit was first on the list, was struggling to find where they all went to start with so printed off the diagram and numbered them so may help people in the future.
http://i252.photobucket.com/albums/hh23/alexb1234/C14AD4EC-6131-4B00-9034-122D4112F0B8.jpg (http://s252.photobucket.com/user/alexb1234/media/C14AD4EC-6131-4B00-9034-122D4112F0B8.jpg.html)

Once I figured out where they all went I got them all tacked in place.
http://i252.photobucket.com/albums/hh23/alexb1234/076CC452-F919-4C98-8F24-9A4DC2F1A94B.jpg (http://s252.photobucket.com/user/alexb1234/media/076CC452-F919-4C98-8F24-9A4DC2F1A94B.jpg.html)

http://i252.photobucket.com/albums/hh23/alexb1234/663A5B98-4CE0-4071-8138-13721FA34FA2.jpg (http://s252.photobucket.com/user/alexb1234/media/663A5B98-4CE0-4071-8138-13721FA34FA2.jpg.html)
Strut tops aren't on the drawing but pretty simple where they go, I bolted them down in position to be sure of alignment this held it all in place for welding also.

http://i252.photobucket.com/albums/hh23/alexb1234/EE9A6CAA-1823-4D86-8F02-E5BA7011223E.jpg (http://s252.photobucket.com/user/alexb1234/media/EE9A6CAA-1823-4D86-8F02-E5BA7011223E.jpg.html)

Above shows Plates 1 - Drivers side chassis leg (again pretty simple to locate) and plate 4 - drivers side tie bar (remember to weld on the underside) I bolted the tie bar plate in place before welding again to be sure the hole lines up then followed the drill through the front member.

http://i252.photobucket.com/albums/hh23/alexb1234/00F38EC6-6876-4FBD-B528-0B4BC2A2C447.jpg (http://s252.photobucket.com/user/alexb1234/media/00F38EC6-6876-4FBD-B528-0B4BC2A2C447.jpg.html)

Above shows plates 2 - passenger side chassis leg and plate 3 passenger tie bar the same as the drivers side.

http://i252.photobucket.com/albums/hh23/alexb1234/1B9BDF1B-511B-4746-B9E2-1917583B4DF6.jpg (http://s252.photobucket.com/user/alexb1234/media/1B9BDF1B-511B-4746-B9E2-1917583B4DF6.jpg.html)

Plate 10 - drivers side (look inside the wheel arch and it will be obvious where it goes)

http://i252.photobucket.com/albums/hh23/alexb1234/64051557-EDE3-47EA-B415-F53457C32D41.jpg (http://s252.photobucket.com/user/alexb1234/media/64051557-EDE3-47EA-B415-F53457C32D41.jpg.html)
Plate 9 - passenger side (look inside the wheel arch and it will be obvious where it goes)

Theres a few I didn't get pictures of but will use people's existing pictures (hope nobody minds just for info purposes) and try and explain where they are.

[millworm]

looks good need to do mine, been occupied with the daily nova and escort recently :(

[ABoresta]

Once all the plates were tacked in I got onto stitch welding them and the rest of the engine bay.

http://i252.photobucket.com/albums/hh23/alexb1234/90AB47E0-EC64-4FFB-A4D2-7FDB24FBAB2C.jpg (http://s252.photobucket.com/user/alexb1234/media/90AB47E0-EC64-4FFB-A4D2-7FDB24FBAB2C.jpg.html)

http://i252.photobucket.com/albums/hh23/alexb1234/F6D2C145-9119-4627-A169-CF618E994188.jpg (http://s252.photobucket.com/user/alexb1234/media/F6D2C145-9119-4627-A169-CF618E994188.jpg.html)

http://i252.photobucket.com/albums/hh23/alexb1234/95FA95EB-CEFC-49B1-BB15-DBF9167E6E0C.jpg (http://s252.photobucket.com/user/alexb1234/media/95FA95EB-CEFC-49B1-BB15-DBF9167E6E0C.jpg.html)

http://i252.photobucket.com/albums/hh23/alexb1234/3CC2D490-C8E3-47A6-8CB1-6D58A9EFAAF6.jpg (http://s252.photobucket.com/user/alexb1234/media/3CC2D490-C8E3-47A6-8CB1-6D58A9EFAAF6.jpg.html)
(ignore the pink mat haha)

http://i252.photobucket.com/albums/hh23/alexb1234/8AFAABC6-303E-4C92-B932-98BF5CB04EC7.jpg (http://s252.photobucket.com/user/alexb1234/media/8AFAABC6-303E-4C92-B932-98BF5CB04EC7.jpg.html)
new clutch plate welded on in place at a slight angle to get as much clearance as possible.

Feet up and think what I'm going to do about the bulkhead for the bike carbs, currently cut out locally so they fit until I decide what to do as I wanted to keep as much as I could to hide some wiring, windscreen washer bottle etc and I want to keep the heater blower in place too.

http://i252.photobucket.com/albums/hh23/alexb1234/2E50FF01-2E52-40D7-94B5-227DEA764D90.jpg (http://s252.photobucket.com/user/alexb1234/media/2E50FF01-2E52-40D7-94B5-227DEA764D90.jpg.html)

Then etch primer on all the plates and welds

http://i252.photobucket.com/albums/hh23/alexb1234/E528956B-641D-45F9-B760-62FDB84B678B.jpg (http://s252.photobucket.com/user/alexb1234/media/E528956B-641D-45F9-B760-62FDB84B678B.jpg.html)

http://i252.photobucket.com/albums/hh23/alexb1234/A179BD93-2DD8-445D-871D-C250B75F8232.jpg (http://s252.photobucket.com/user/alexb1234/media/A179BD93-2DD8-445D-871D-C250B75F8232.jpg.html)

http://i252.photobucket.com/albums/hh23/alexb1234/4915D804-0425-4A1B-A76C-0990C9307B4F.jpg (http://s252.photobucket.com/user/alexb1234/media/4915D804-0425-4A1B-A76C-0990C9307B4F.jpg.html)

[ABoresta]

Sump gasket and arp rod bolts fitted after a cam belt, idlers, tensioner and water pump replaced (didn't bother with a picture with that it isn't interesting)
http://i252.photobucket.com/albums/hh23/alexb1234/CE2C2C0F-A9DA-411A-8292-F240933E5581.jpg (http://s252.photobucket.com/user/alexb1234/media/CE2C2C0F-A9DA-411A-8292-F240933E5581.jpg.html)

New inlet manifold fitted and found out it's a bodge and doesn't line up to the carbs when it's bolted to the engine so trying to figure out what to do right now but a test fit with some fuel hose was done just to see for now
http://i252.photobucket.com/albums/hh23/alexb1234/C27D7848-6ECF-488B-9BB0-E71A7B01B92C.jpg (http://s252.photobucket.com/user/alexb1234/media/C27D7848-6ECF-488B-9BB0-E71A7B01B92C.jpg.html)

I think they are sitting too far away but I will sort that before the engine goes back in
http://i252.photobucket.com/albums/hh23/alexb1234/2E9FC6BA-D0A3-4953-8B8A-3160912F8860.jpg (http://s252.photobucket.com/user/alexb1234/media/2E9FC6BA-D0A3-4953-8B8A-3160912F8860.jpg.html)

[ABoresta]

In the process of making some solid engine mounts with liquid casting rubber, on the shore scale apparently this is between a bowling ball and poly bushes so should be pretty tough haha, doesn't look to neat at the moment but I will tidy them up when they are done.

http://i252.photobucket.com/albums/hh23/alexb1234/F1D72AD4-A079-4156-9826-F5DE5F103B1E.jpg (http://s252.photobucket.com/user/alexb1234/media/F1D72AD4-A079-4156-9826-F5DE5F103B1E.jpg.html)

And my little order from H&H ignition turned up this weekend so on to fitting these bike carbs once and for all!

http://i252.photobucket.com/albums/hh23/alexb1234/A79D79B9-5C37-4383-AC43-1B0BEB10239E.jpg (http://s252.photobucket.com/user/alexb1234/media/A79D79B9-5C37-4383-AC43-1B0BEB10239E.jpg.html)

[ABoresta]

Finally making progress hopefully I will be ready in time for PVS!

So First step is to get the engine back in:
http://i252.photobucket.com/albums/hh23/alexb1234/5957E64A-CED3-43BE-9502-F91DE7B7F65F.jpg (http://s252.photobucket.com/user/alexb1234/media/5957E64A-CED3-43BE-9502-F91DE7B7F65F.jpg.html)

Sitting pretty level I think...
http://i252.photobucket.com/albums/hh23/alexb1234/61DC2F35-B626-438C-AD25-10610CAD887D.jpg (http://s252.photobucket.com/user/alexb1234/media/61DC2F35-B626-438C-AD25-10610CAD887D.jpg.html)

And the clearance for the alternator belt looks a lot better now I can fit my finger down between them :)
http://i252.photobucket.com/albums/hh23/alexb1234/787F453B-ACC0-403B-8000-B9B46AC3CD0B.jpg (http://s252.photobucket.com/user/alexb1234/media/787F453B-ACC0-403B-8000-B9B46AC3CD0B.jpg.html)

Then onto test fitting the bike carbs for the first time :D
http://i252.photobucket.com/albums/hh23/alexb1234/EABEF179-DC19-4939-A253-659C92E1DBC7.jpg (http://s252.photobucket.com/user/alexb1234/media/EABEF179-DC19-4939-A253-659C92E1DBC7.jpg.html)

They get a bit close to the heater blower motor but I want to keep it (for now any ways) so I'm happy it just fits
http://i252.photobucket.com/albums/hh23/alexb1234/498DCF92-41C9-4CD7-BD6C-9AB5BAD80105_1.jpg (http://s252.photobucket.com/user/alexb1234/media/498DCF92-41C9-4CD7-BD6C-9AB5BAD80105_1.jpg.html)

And a little arty shot with my oil catch can where I'm thinking of mounting it? Any suggestions where else I could fit it?
http://i252.photobucket.com/albums/hh23/alexb1234/0AC2F805-0DE3-4B0D-843A-40CD3F8C3D56.jpg (http://s252.photobucket.com/user/alexb1234/media/0AC2F805-0DE3-4B0D-843A-40CD3F8C3D56.jpg.html)

And my gear knob turned up today so I went about fitting that at work :)
http://i252.photobucket.com/albums/hh23/alexb1234/5AC89666-5979-4A32-8FF1-82838A49B676.jpg (http://s252.photobucket.com/user/alexb1234/media/5AC89666-5979-4A32-8FF1-82838A49B676.jpg.html)

[Al1exx]

Looking good mate you're a whizz wi the welder!

[Iain]

Sorry a bit late to say but the holes in the strengthening plates are for puddle welding into...

Catch tank location looks good

[BRoadGhost]

Before welding you should bring all surfaces back to bare metal & you're not using quite enough gas. Is that epoxy in the engine mounts?

Look forward to seeing more :)

[ABoresta]

Looking good mate you're a whizz wi the welder!

Doing the best I can with gas less mate wish I had the welder from uni here or the tig would be even better!!!!

[ABoresta]

Sorry a bit late to say but the holes in the strengthening plates are for puddle welding into...

Catch tank location looks good

Yeah I know mate but where I had my little ding last year the chassis legs aren't perfectly straight so I didn't want to put loadssssss of weld in the holes I did the majority of them though :)

and yeah I quite like it there but better test fit the headlight first lol

[ABoresta]

Before welding you should bring all surfaces back to bare metal & you're not using quite enough gas. Is that epoxy in the engine mounts?

Look forward to seeing more :)


Its a gasless welder not the neatest but I'm getting strong welds out of it and when I spend the time to clean them up they look ok... I was being lazy not cleaning up the metal and made more work in the long run oopsy!

It is polyurethane in the engine mounts what my mate used on his e36 dirt car and worked a treat these are a little harder than his though

[ABoresta]

I have done so much more work since this thread and haven’t got pictures any more of the updates. Might have to get it going again

[Nova_Tek]

Nice project and something a little different. Don't see many black Novas :thumb: