Steve's Lexmaul widebody

[duick]

Hi
It's been a while since I've not posted a WIP here.
People that know me for years, know that I've always got a WIP ongoing. And if one is finished, the next one is started (or even a few at the same time :) )

This year, I did a quick WIP by converting this

http://www.opel-corsa-a.com/Joy-Faltdach/Faltdach.jpg

to this

http://www.opel-corsa-a.com/Joy-Faltdach/IMG_3929.JPG

Some have surely seen it at Billing at the PNG stand.

Well, since a while, I had another crazy idea in mind, as I have a lot of unused parts in stock. and it makes no sense to keep everything hidden in stock lol
This Corsa was for sale, not far from my home. Been built and owned for 15 years by the owner, but of the road for some years

http://www.opel-corsa-a.com/Lexmaul/IMG_9165.JPG

The price was too good, by selling all unnecessary parts (cage, wheels, seats and a few more) the shell cost me less than nothing.
And while the Corsa with folding roof would be at the painter, I would have enough time (about 6 weeks) to prepare this shell for painting!!
That was the plan. But as you know, normally some things are unplanned :wtf:

I started to disassemble the car and found a LOT of sh....!!!
The whole wiring looked like this
http://www.opel-corsa-a.com/Lexmaul/IMG_9318.JPG

So I ditched it completely.

Then I found this
http://www.opel-corsa-a.com/Lexmaul/IMG_9308.JPG

and this
http://www.opel-corsa-a.com/Lexmaul/IMG_9309.JPG

http://www.opel-corsa-a.com/Lexmaul/IMG_9311.JPG

http://www.opel-corsa-a.com/Lexmaul/IMG_9324.JPG


But as the shell was quite solid in some important areas, I decided to keep it.

http://www.opel-corsa-a.com/Lexmaul/IMG_9312.JPG

[duick]

Next step was to replace the complete trunk panel

Out came the rusty one
http://www.opel-corsa-a.com/Lexmaul/IMG_9367.JPG

And in the new one

http://www.opel-corsa-a.com/Lexmaul/IMG_9377.JPG

With all the rust and riveted patches on the front, there was only one solution!
This one!

http://www.opel-corsa-a.com/Lexmaul/IMG_9378.JPG

That gave me a look in the chassis legs, that were rust free :)

http://www.opel-corsa-a.com/Lexmaul/IMG_9382.JPG

http://www.opel-corsa-a.com/Lexmaul/IMG_9383.JPG

And took this genuine one out of the stock

http://www.opel-corsa-a.com/Lexmaul/IMG_3654.JPG

Put it in, alligned and checked with bonnet and wings

http://www.opel-corsa-a.com/Lexmaul/IMG_3659.JPG

and then spot welded

[duick]

I saw that someone had tried to "repair" the left rear arch.
As I had that plan, I didn't care, as both would need a bigger cutout.

Of came all that patch, what a mess :mad: That's the result after a few years, if someone patches a repair panel over the rust!!
http://www.opel-corsa-a.com/Lexmaul/IMG_9386.JPG

http://www.opel-corsa-a.com/Lexmaul/IMG_9388.JPG

Cut it larger, did a lot of measuring and drilled some holes

http://www.opel-corsa-a.com/Lexmaul/IMG_9392.JPG

To get these attached

http://www.opel-corsa-a.com/Lexmaul/IMG_9390.JPG

http://www.opel-corsa-a.com/Lexmaul/IMG_9391.JPG

With some small modifications on the (new) front panel, I got the wings fitted

http://www.opel-corsa-a.com/Lexmaul/IMG_9387.JPG

[duick]

When cutting the rear arches, I had a look in the LH sill and what I saw confused me :confused:
I saw 2 layers of metal, very strange :confused:
And I saw rivets!!!!! ahhhhhhhhhhhhhhhhhhhhhhhhh :mad:

Ok, hammer and chisel and 5 minutes later it looked like this

http://www.opel-corsa-a.com/Lexmaul/IMG_9393.JPG

http://www.opel-corsa-a.com/Lexmaul/IMG_9396.JPG

Someone had again tried to "repair" the sills by riveting the lower part of a repair panel over the rust and plastering everything :mad::mad:

Out with that mess
http://www.opel-corsa-a.com/Lexmaul/IMG_9397.JPG

and cut out the rest of the rust on the inner sill
http://www.opel-corsa-a.com/Lexmaul/IMG_9394.JPG

Some time later ...
http://www.opel-corsa-a.com/Lexmaul/IMG_9399.JPG


As I had now a doubt about the RH sill, I checked it with the camera, discovered the same mess, and opened it :mad:
And again a few hours later

http://www.opel-corsa-a.com/Lexmaul/IMG_9403.JPG

[Benn]

Looking like a great project. Arches/bumper ends are different. Nice work on the metal work, must be great having that in stock.

[duick]

Then I modified the inner arches for the widebody

http://www.opel-corsa-a.com/Lexmaul/IMG_9400.JPG

And due to some rust on the turrets, I had to take of these braces to repair the turrets. I then welded in new braces

http://www.opel-corsa-a.com/Lexmaul/IMG_9398.JPG

http://www.opel-corsa-a.com/Lexmaul/IMG_9401.JPG


Finally, as I had some van panels in stock, the idea was to transform it to a van
1 new and 1 used panel

http://www.opel-corsa-a.com/Lexmaul/IMG_9406.JPG

http://www.opel-corsa-a.com/Lexmaul/IMG_9407.JPG

And an early bootlid without wiper

http://www.opel-corsa-a.com/Lexmaul/IMG_9405.JPG

[Benn]

Nice,

[duick]

2 weeks ago, the shell and the parts came back from the painter


http://www.opel-corsa-a.com/Lexmaul/IMG_4058.JPG

http://www.opel-corsa-a.com/Lexmaul/IMG_4057.JPG

[Benn]

Unsure on the colour myself, but looks like a great job. Top work.

[duick]

a few updates, about the progress of the last weeks:

Rebuilt the rear axle, powdercoated beam and a lot of new parts:

http://www.opel-corsa-a.com/Lexmaul/IMG_4084.JPG

a few more powdercoated parts

http://www.opel-corsa-a.com/Lexmaul/IMG_4087.JPG

http://www.opel-corsa-a.com/Lexmaul/IMG_4088.JPG

Cleaned up and painted the underbody and refitted the tank and rear axle

http://www.opel-corsa-a.com/Lexmaul/IMG_4090.JPG

Same treatment for the front suspension

http://www.opel-corsa-a.com/Lexmaul/IMG_4102.JPG

Pedal box also as new

http://www.opel-corsa-a.com/Lexmaul/IMG_4091.JPG

Firewall insulation and GTE loom fitted

http://www.opel-corsa-a.com/Lexmaul/IMG_4093.JPG

Also the GTE dash

http://www.opel-corsa-a.com/Lexmaul/IMG_4097.JPG

And finally the front wings and the Exip wheels

http://www.opel-corsa-a.com/Lexmaul/IMG_4101.JPG

[slimtater]

Nice project - needing less work than my Sport shell!!

[pete17]

Loving the grey and black combo of paint, top work mate very impressed cant wait to see what it looks like when you have finished it:thumb:

[ledpen]

Very nice project

[Royston]

Looking good Steve, be nice to have a run back over your way............one day!

[sport]

Looking good Steve something different

[Southie]

The colour looks fantastic and it looks a very high class job to say the least, what spec is the engine going to be?

[duick]

Engine will be a standard E16SE

[blue_peg_16v]

Very nice love the colour

[Iain]

Very unusual, love it.

[Benn]

Looking good, love how deep the rear bumper is gonna be. You'll have a handy seat there..lol

[Balley]

Looks great, well done.

[duick]

Finally an update :d
Body panels are all on the car now.
Front completed:

http://www.opel-corsa-a.com/Lexmaul/IMG_4161.JPG

and the rear too:
http://www.opel-corsa-a.com/Lexmaul/IMG_4162.JPG

just need to align the lid and fit the SR spoiler

Yes, I know, rear tyres will not stay on the car lollol I have no tyres yet for the 9" wheels. not easy to get 245 wide ones for 15"

Engine and gearbox are also in.
http://www.opel-corsa-a.com/Lexmaul/IMG_4160.JPG

Some things were still missing on this picture, but in the meantime it's fully finished

Van panels are also in, only missing the carpet. will get it next week
http://www.opel-corsa-a.com/Lexmaul/IMG_4163.JPG

[Plug]

I want this kit and van!!! Cracking work Steve as per normal !!

[Benn]

Looks awesome. Love how wide the rear arches are.

[totalnova]

Looks lovely can't wait to see some nice wide wheels filling those rear arches.

[krobinson]

Looks great Steve :)

[duick]

Finally sorted the engine problems and other gremlins
So, the Corsa is nearly ready to get Mot'ed


Enjoy the pics :d

http://www.opel-corsa-a.com/Lexmaul/Lexmaul1.JPG

http://www.opel-corsa-a.com/Lexmaul/Lexmaul2.JPG

http://www.opel-corsa-a.com/Lexmaul/Lexmaul3.JPG

http://www.opel-corsa-a.com/Lexmaul/Lexmaul4.JPG

http://www.opel-corsa-a.com/Lexmaul/Lexmaul5.JPG

http://www.opel-corsa-a.com/Lexmaul/Lexmaul6.JPG

[Southie]

Absolutely love it and would love to own this :cool:

[kevy.m]

Cool I like it makes me want to wide body my saloon prob wont look as nice as the hatch though!!! nice job mate :thumb:

[Plug]

Amazing work as normal Steve!!

i see you finally managed to get some gte door cards that haven't been cut about aswell it was you looking for another set ??

[Benn]

Love that.

[duick]

i see you finally managed to get some gte door cards that haven't been cut about aswell it was you looking for another set ??

Yes, a colleague had a set in his storage. But if I could find another set for him, that would be perfect

[L33 LEG]

Absolutely love this! Excellent work, I want it lol

[Iain]

This is glorious

[Royston]

Great job, looking forward to see it at Billing!

[Rickyb]

absolutely love this what an awesome project.
Rick