Nova Gsi turbo project. 10 years now

[jackosnovaturbo]

I bought this car in 2008 as a 1.6 GSI from Mark Ridley (novacabrio), former owner was Rob Delicata. I have lost a lot of the pictures of the car when I bought it due to photobucket but THis is going to be a huge thread, I have hundreds of pictures of the reconstruction and it's gonna take a long time to get all this into the thread. Current status is shell just about finished, and the manifolds are being made.

Ok, to the pictures.

When I bought it 2008
https://i.ibb.co/BT6Hfp2/371.jpg

https://i.ibb.co/Ch9Bw7Z/372.jpg (https://ibb.co/Tm0cw8S)

I had only changed the wheels

[jackosnovaturbo]

After the c20let conversion and a few good years, The rot had taken hold and the car had come to Slovenia with me. A cheap 1.5d with very good bodywork was found. But how do I keep the GSI alive?

https://i.ibb.co/FHng2yp/IMG-4898.jpg

[rickygolf83]

Cut good metal from the diesel shell, cut bad metal out the gsi and replace with said good metal from the diesel!

Hopefully plenty pics too come

Sent from my SM-G950F using Tapatalk

[andybishop]

Looking forward to seeing the progress on this, Rob is a good mate of mine, he’s glad it’s still about!!

[Robnut]

Good luck with getting her back on the road. Do miss here but selling allowed me to start my Mini project

[jackosnovaturbo]

Good luck with getting her back on the road. Do miss here but selling allowed me to start my Mini project

That's great that you found this thread, I hope I can do the car justice. I love mini's, my friend used to have a hayabusa powered one.

I always wonder what happened to my previous Nova's J484 KTN https://i.ibb.co/sCtGxNW/511.jpg (https://ibb.co/LrvWjcN), 1998-2006.

And Breeny's old one J880 JPO, 2005-2007.

https://i.ibb.co/fnb4L8G/337.jpg (https://ibb.co/hZkDwX1)
https://i.ibb.co/3hnzd6R/336.jpg (https://ibb.co/MNm6SwB)
https://i.ibb.co/HhshtxB/332.jpg (https://ibb.co/Sf8ftd5)

I have had the GSI since 2008 and was in great condition visually, pic before I bought it
https://i.ibb.co/qWT1JmK/shineyblackgsi.jpg (https://ibb.co/rcDyd5Y)

It was solid enough to put my turbo engine in and fit a chassis plating kit but after 4 years of use It was confined to the garage, needing a long list of jobs doing and the bodywork was going downhill due to living by the sea for a couple of years and the car living outside. I almost sold it to a friend for £2500 in 2012 but I'm glad I didn't now. When I moved to Slovenia in 2012 I had it shipped here in a truck with the rest of my removals.

https://i.ibb.co/JqvcsqD/IMG-2548.jpg (https://ibb.co/428FV2h)

https://i.ibb.co/TcWLbbF/IMG-2547.jpg (https://ibb.co/1Zz6ddw)

https://i.ibb.co/gMxVhfR/IMG-2551.jpg (https://ibb.co/Lz35HcZ)
https://i.ibb.co/XCmnrrr/IMG-2553.jpg (https://ibb.co/FDGQLLL)

Since then It had only been let out a couple of times

https://i.ibb.co/X4RNNV8/IMG-2658.jpg (https://ibb.co/CtGNNW2)

https://i.ibb.co/t3xkRCX/IMG-2294.jpg (https://ibb.co/qxWX615)

https://i.ibb.co/qW2bWbG/IMG-2297.jpg (https://ibb.co/cCszCz5)

https://i.ibb.co/0K8BRfW/IMG-2299.jpg (https://ibb.co/dt1bwQ3)

[jackosnovaturbo]

Knocked garage down 2013


https://i.ibb.co/hMTZGm2/IMG-3045.jpg (https://ibb.co/dcHLN5k)


https://i.ibb.co/k5xgj7b/IMG-3260.jpg (https://ibb.co/XjbZ1Q0)

Donor car sourced, £500

https://i.ibb.co/94GMYPW/slocorsa5.jpg (https://ibb.co/Ksm1ynW)


https://i.ibb.co/CbV92YC/slocorsa2.jpg (https://ibb.co/zXP2JB9)

https://i.ibb.co/yXKG8Hn/slocorsa3.jpg (https://ibb.co/Btvdg0V)

https://i.ibb.co/dm3Vnyy/slocorsa1.jpg (https://ibb.co/z6LBKww)

https://i.ibb.co/QmCMqKW/slocorsa4.jpg (https://ibb.co/MNG7jCz)

https://i.ibb.co/J7BZGjK/IMG-4532.jpg (https://ibb.co/6PnQT0m)
Snow is slowly eating novas, need garage!

https://i.ibb.co/30v61TF/IMG-3838.jpg (https://ibb.co/p3QV21K)

[jackosnovaturbo]

Started dismantling the white one for parts


https://i.ibb.co/47Mp3ZJ/IMG-4908.jpg (https://ibb.co/hyHVwRC)


https://i.ibb.co/0Cz57f0/IMG-4907.jpg (https://ibb.co/1r4cg9C)


https://i.ibb.co/tcqYW1j/IMG-4909.jpg (https://ibb.co/1KrRw4y)


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https://i.ibb.co/qsfp51P/IMG-4912.jpg (https://ibb.co/bBZXJd8)


https://i.ibb.co/NL8fG3F/IMG-4961.jpg (https://ibb.co/4j6C0fF)


https://i.ibb.co/vzwf2zk/IMG-4962.jpg (https://ibb.co/7yYB7yK)


https://i.ibb.co/H77Cn56/IMG-4960.jpg (https://ibb.co/4WW2Phz)


https://i.ibb.co/1sJLWn8/IMG-4959.jpg (https://ibb.co/Gs30SJc)


https://i.ibb.co/Tcc8jwR/IMG-4964.jpg (https://ibb.co/kKK8bG0)


https://i.ibb.co/FmX9qy9/IMG-4965.jpg (https://ibb.co/YPX6T16)


https://i.ibb.co/FmX9qy9/IMG-4965.jpg (https://ibb.co/YPX6T16)

[jackosnovaturbo]

Only allowed 15 pics per post. This could take quite some time.



https://i.ibb.co/bKSL2ZQ/IMG-4966.jpg (https://ibb.co/MCYpG4Z)


https://i.ibb.co/LRc6WyZ/IMG-4969.jpg (https://ibb.co/JtG24Ts)


https://i.ibb.co/Y826223/IMG-4968.jpg (https://ibb.co/Gk7X770)


https://i.ibb.co/LRc6WyZ/IMG-4969.jpg (https://ibb.co/JtG24Ts)


https://i.ibb.co/Y826223/IMG-4968.jpg (https://ibb.co/Gk7X770)


https://i.ibb.co/c1H2SNz/IMG-4967.jpg (https://ibb.co/PNn1v5B)


https://i.ibb.co/6tVbmjr/IMG-4970.jpg (https://ibb.co/rpTMmDF)


https://i.ibb.co/tPGk8X6/IMG-4971.jpg (https://ibb.co/fGgB4vW)


https://i.ibb.co/87vzhBH/IMG-4972.jpg (https://ibb.co/hmQXqMS)


https://i.ibb.co/41JxNb3/IMG-4975.jpg (https://ibb.co/Z2NCTQ7)


https://i.ibb.co/bHszRDt/IMG-4974.jpg (https://ibb.co/CJbhsDL)


https://i.ibb.co/KwQNknz/IMG-4973.jpg (https://ibb.co/74Tg5hN)


https://i.ibb.co/wR62Lbg/IMG-4996.jpg (https://ibb.co/L8psPqR)

[torquey]

White one looks a mint shell. Shame to cut it up.

[jackosnovaturbo]

https://i.ibb.co/0Mh4zpm/IMG-4995.jpg (https://ibb.co/Z8W4bRG)


https://i.ibb.co/dGK9Yf5/IMG-4994.jpg (https://ibb.co/yWsTjNQ)





https://i.ibb.co/f8wvc2N/IMG-5432.jpg (https://ibb.co/Q8wd5fH)


https://i.ibb.co/hKwsND0/IMG-5436.jpg (https://ibb.co/brD1Vzt)


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https://i.ibb.co/tKMsNn6/IMG-5434.jpg (https://ibb.co/C857X4y)


https://i.ibb.co/9cCWDhJ/IMG-5433.jpg (https://ibb.co/6rfFM82)


https://i.ibb.co/YhV8Zb7/IMG-5437.jpg (https://ibb.co/TtNRLrB)


https://i.ibb.co/GVZZvqZ/IMG-5438.jpg (https://ibb.co/19CCfkC)


https://i.ibb.co/q1qzng5/IMG-5439.jpg (https://ibb.co/C0Cqt92)

https://i.ibb.co/L0KJNWJ/IMG-5444.jpg (https://ibb.co/51ZnKyn)

https://i.ibb.co/1d0qzGk/IMG-5443.jpg (https://ibb.co/b26Bb5k)


https://i.ibb.co/Wnqh3gr/IMG-5442.jpg (https://ibb.co/1Zhgn8C)






So Finally stripped

[jackosnovaturbo]

Some double post pictures, sorry, my head is spinning with this, it's been a long time since I was posting IMG links to discussion forums.

Now time to assess the chop on the GSI, CAREFUL!

https://i.ibb.co/fvs11SG/IMG-5447.jpg (https://ibb.co/Zm0LLJ1)


https://i.ibb.co/qDQ5Wq5/IMG-5019.jpg (https://ibb.co/grKVPqV)


https://i.ibb.co/1sbh92z/IMG-5023.jpg (https://ibb.co/8zXTj8Y)


https://i.ibb.co/X487kzv/IMG-5021.jpg (https://ibb.co/qn5NFRP)


https://i.ibb.co/F4qmLDw/IMG-5020.jpg (https://ibb.co/nM86NLc)


smokey


https://i.ibb.co/1bp5z4y/IMG-5024.jpg (https://ibb.co/GF1LHrY)


and done


https://i.ibb.co/qRfjhN5/IMG-5025.jpg (https://ibb.co/7G5CBn4)


TEST FIThttps://i.ibb.co/6R6ygR2/IMG-5028.jpg (https://ibb.co/gMsrzMG)


https://i.ibb.co/zN8YSYt/IMG-5029.jpg (https://ibb.co/6Nvx4xq)


https://i.ibb.co/Vx6cjgM/IMG-5030.jpg (https://ibb.co/ScS4stV)


https://i.ibb.co/LkbN3yP/IMG-5031.jpg (https://ibb.co/kHkmtTy)


A lot of measurements and a bit of luck?

[jackosnovaturbo]

Time to check the fit up



https://i.ibb.co/9W50XLG/IMG-5041.jpg (https://ibb.co/gJK81p6)


https://i.ibb.co/42NLw9c/IMG-5040.jpg (https://ibb.co/XDJPfN9)


https://i.ibb.co/xgDgn3V/IMG-5038.jpg (https://ibb.co/hdydGCp)


https://i.ibb.co/hWV0TMK/IMG-5033.jpg (https://ibb.co/9TWPdvq)


https://i.ibb.co/8KYXRbq/IMG-5045.jpg (https://ibb.co/M2B9jfr)


https://i.ibb.co/qFYf9s0/IMG-5046.jpg (https://ibb.co/M5k4pV8)


https://i.ibb.co/r6XLYfY/IMG-5043.jpg (https://ibb.co/7W0TPNP)


And if anyone is wondering why such extreme measures were taken? well looking back at it now, I'm not sure , probably would have been easier ways of doing it, but with a lot of rusty seams on the back half of the black one, it would have meant removing all of the outer panels and piecing big sections of the inner skin, in weird places like the lower window frame and tailgate. The back panel on the white one was immaculate.

[jackosnovaturbo]

Closer inspection of the white one reveals some rust, just where I need some better clearance for my rear coilovers that were touching when the car was jacked up

https://i.ibb.co/GFgFWqw/IMG-5047.jpg (https://ibb.co/8XFXrH3)


https://i.ibb.co/0nzrvTW/IMG-5049.jpg (https://ibb.co/4F0p3zD)

[torquey]

Nicely done pal. Should be mint when done.

[jackosnovaturbo]

White one looks a mint shell. Shame to cut it up.

Yeah, It was always bought as a donor, It would have made a nice runaround maybe, a local friend suggested just cutting the numbers out of the gsi????

[torquey]

Needs must I suppose. Looks a lot of work but your making it look easy wish I could make such fast progress on mine.

Sent from my SM-A520F using Tapatalk

[jackosnovaturbo]

I forgot to say that this whole project is tig welded, some bits would be easier with mig, like spot weld, a little less distortion, but harder to dolly and grind/finish the welds.

[jackosnovaturbo]

There is a step missing from the next part where the joins were sleeved with sections from the left over pillars

https://i.ibb.co/pKZ8s6t/IMG-5055.jpg


https://i.ibb.co/DKNJzxF/IMG-5088.jpg


https://i.ibb.co/QkQy37Q/IMG-5089.jpg


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https://i.ibb.co/tmRHVzF/IMG-5113.jpg


https://i.ibb.co/m5x3W5T/IMG-5106.jpg

[jackosnovaturbo]

Sills / arches prep

https://i.ibb.co/pvR588P/IMG-5125.jpg (https://ibb.co/N6mbPP3)


https://i.ibb.co/bNL6qPw/IMG-5126.jpg (https://ibb.co/vLmcgHy)


https://i.ibb.co/BcqdwL0/IMG-5127.jpg (https://ibb.co/2Wgm5qG)


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https://i.ibb.co/cxjsFst/IMG-5134.jpg (https://ibb.co/stZXwXQ)


https://i.ibb.co/HB7M2mS/IMG-5137.jpg (https://ibb.co/k5KryY7)


https://i.ibb.co/HKrQR2M/IMG-5135.jpg (https://ibb.co/x2MQwsc)

[jackosnovaturbo]

WiNKER or W*nker? please use you eye protection?, all night in the eye hospital and eye ball drilled to remove metal fragment. It actually went under my eye protection and into my eye, one week setback

https://i.ibb.co/ZG9jQGC/IMG-5139.jpg
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[jackosnovaturbo]

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https://i.ibb.co/7CWJzY6/IMG-5174.jpg (https://ibb.co/KhqjG03)

[jackosnovaturbo]

Getting scary now

https://i.ibb.co/W5ZRcNT/IMG-5182.jpg (https://ibb.co/B3bYgH1)


https://i.ibb.co/bHzZq0B/IMG-5185.jpg (https://ibb.co/5YByt08)


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https://i.ibb.co/FhY3kFs/IMG-5188.jpg (https://ibb.co/51j4XPY)


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https://i.ibb.co/6Rvjb96/IMG-5190.jpg (https://ibb.co/3yfgW6t)


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https://i.ibb.co/QmwQKsF/IMG-5183.jpg (https://ibb.co/x5TL7VS)

[jackosnovaturbo]

More scary

https://i.ibb.co/HqJBPJ3/IMG-5198.jpg


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[jackosnovaturbo]

https://i.ibb.co/9G6LDGW/IMG-5215.jpg
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[jackosnovaturbo]

Getting somewhere ?

https://i.ibb.co/5vYPHJT/IMG-5233.jpg
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[jackosnovaturbo]

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[jackosnovaturbo]

LMAO battery tray, I'd forgotten about that nightmare, passenger side behind strut was a piece of 3mm gas bottle! solid

[jackosnovaturbo]

https://i.ibb.co/Qf894DN/IMG-5292.jpg


https://i.ibb.co/7VrqS0R/IMG-5300.jpg
https://i.ibb.co/HYFZttZ/IMG-5301.jpg
https://i.ibb.co/wwXT4VN/column1a.jpg
https://i.ibb.co/1RQdVpb/IMG-5302.jpg
https://i.ibb.co/tLwVYg6/IMG-5304.jpg
https://i.ibb.co/28yrNbd/IMG-5305.jpg
https://i.ibb.co/rHLVZnk/IMG-5306.jpg
https://i.ibb.co/VpFjBjV/IMG-5307.jpg
https://i.ibb.co/723Y29m/IMG-5308.jpg
https://i.ibb.co/1q54xqZ/IMG-5309.jpg
https://i.ibb.co/tHgCpqD/IMG-5310.jpg
https://i.ibb.co/0BQfbzP/IMG-5312.jpg
https://i.ibb.co/w0L6Vj9/IMG-5313.jpg

[jackosnovaturbo]

https://i.ibb.co/L8hvf9N/IMG-5317.jpg
https://i.ibb.co/rbTCP1R/IMG-5316.jpg
https://i.ibb.co/Xs7cnfh/IMG-5318.jpg
https://i.ibb.co/xYBy0n7/IMG-5319.jpg
https://i.ibb.co/xhmqsqg/IMG-5320.jpg
https://i.ibb.co/C77xfDW/IMG-5321.jpg
https://i.ibb.co/Fm4fZw6/IMG-5322.jpg
https://i.ibb.co/pXtYzP1/IMG-5323.jpg
https://i.ibb.co/pWFybqR/IMG-5324.jpg
https://i.ibb.co/HgKJn6R/IMG-5328.jpg
https://i.ibb.co/QnktRBV/IMG-5329.jpg
https://i.ibb.co/HCtx1Mf/IMG-5330.jpg
https://i.ibb.co/0VCdTgw/IMG-5331.jpg
https://i.ibb.co/JsqN6ZC/IMG-5332.jpg
https://i.ibb.co/0ZYyqBk/IMG-5333.jpg

[jackosnovaturbo]

https://i.ibb.co/54HWZDN/IMG-5338.jpg
https://i.ibb.co/LdTr9tX/IMG-5339.jpg
https://i.ibb.co/7JQyNYZ/IMG-5340.jpg
https://i.ibb.co/bR3JFmP/IMG-5341.jpg
https://i.ibb.co/0fMPCtw/IMG-5342.jpg
https://i.ibb.co/QcrL7hb/IMG-5343.jpg
https://i.ibb.co/x7tSsQP/IMG-5344.jpg
https://i.ibb.co/6YwH6WN/IMG-5345.jpg
https://i.ibb.co/R4TqXvk/IMG-5346.jpg
https://i.ibb.co/G5WtQCG/IMG-5347.jpg
https://i.ibb.co/t8yhBVy/IMG-5348.jpg
https://i.ibb.co/m65nFbP/IMG-5349.jpg
https://i.ibb.co/rkyngZs/IMG-5350.jpg
https://i.ibb.co/Lkvqq5S/IMG-5352.jpg

[jackosnovaturbo]

Endurance posting session, 15 pics at a time

[jackosnovaturbo]

Double post

[jackosnovaturbo]

https://i.ibb.co/mhGbnNm/IMG-5353.jpg
https://i.ibb.co/r2WLPVS/IMG-5354.jpg
https://i.ibb.co/VL0QHV2/IMG-5355.jpg
https://i.ibb.co/pbx4PpS/IMG-5356.jpg
https://i.ibb.co/Pgt5nn1/IMG-5357.jpg
https://i.ibb.co/St7vs23/IMG-5358.jpg
https://i.ibb.co/xgNCzwr/IMG-5359.jpg
https://i.ibb.co/sj1JSpz/IMG-5360.jpg
https://i.ibb.co/VW5CMRz/IMG-5361.jpg
https://i.ibb.co/X56FF8T/IMG-5363.jpg
https://i.ibb.co/FHdmrqk/IMG-5367.jpg

[jackosnovaturbo]

https://i.ibb.co/mhGbnNm/IMG-5353.jpg
https://i.ibb.co/r2WLPVS/IMG-5354.jpg
https://i.ibb.co/VL0QHV2/IMG-5355.jpg
https://i.ibb.co/pbx4PpS/IMG-5356.jpg
https://i.ibb.co/Pgt5nn1/IMG-5357.jpg
https://i.ibb.co/St7vs23/IMG-5358.jpg
https://i.ibb.co/xgNCzwr/IMG-5359.jpg
https://i.ibb.co/sj1JSpz/IMG-5360.jpg
https://i.ibb.co/VW5CMRz/IMG-5361.jpg
https://i.ibb.co/X56FF8T/IMG-5363.jpg
https://i.ibb.co/FHdmrqk/IMG-5367.jpg

[jackosnovaturbo]

https://i.ibb.co/V9RDzgH/IMG-5389.jpg (https://ibb.co/h9bH4BX)
https://i.ibb.co/fHCfGrG/IMG-5390.jpg (https://ibb.co/3c02YSY)
https://i.ibb.co/3TVdW0V/IMG-5391.jpg (https://ibb.co/dfXM6QX)
https://i.ibb.co/X3bGkV4/IMG-5392.jpg (https://ibb.co/5n6Jx29)
https://i.ibb.co/mDzwWt5/5995065997-960b138c5d-b.jpg (https://ibb.co/TvhS3RM)
https://i.ibb.co/W52Mgk9/IMG-5393.jpg (https://ibb.co/F3Dyg5v)
https://i.ibb.co/JCMXyfy/IMG-5394.jpg (https://ibb.co/V3PXQ7Q)
https://i.ibb.co/NSjHHpH/IMG-5395.jpg (https://ibb.co/xHjRRGR)
https://i.ibb.co/7X6kdsx/IMG-5396.jpg (https://ibb.co/vHKX60C)
https://i.ibb.co/NTQ0NxB/IMG-5397.jpg (https://ibb.co/419bSWr)
https://i.ibb.co/5B6b1cy/IMG-5923.jpg (https://ibb.co/pJxY1X8)
https://i.ibb.co/JRLLz5k/IMG-5398.jpg (https://ibb.co/N6hhLZY)
https://i.ibb.co/qJGNWbd/IMG-5399.jpg (https://ibb.co/vX53Q2H)
https://i.ibb.co/hZL1N52/IMG-5400.jpg (https://ibb.co/b2QRVhN)
https://i.ibb.co/HBf3Gh9/IMG-5401.jpg (https://ibb.co/2W1HcZp)

[jackosnovaturbo]

https://i.ibb.co/JjwTzvK/IMG-5402.jpg (https://ibb.co/ZzprhBV)
https://i.ibb.co/bm0qsDQ/IMG-5403.jpg (https://ibb.co/F3rN5Cm)
https://i.ibb.co/rFKR2Lv/IMG-5404.jpg (https://ibb.co/0mpRyWQ)
https://i.ibb.co/640X4n5/IMG-5405.jpg (https://ibb.co/YtB0tRG)
https://i.ibb.co/23LLx8J/IMG-5406.jpg (https://ibb.co/gZXXNvY)
https://i.ibb.co/9pKVf2C/IMG-5407.jpg (https://ibb.co/Zf4YwKk)
https://i.ibb.co/vDSrSGF/IMG-5408.jpg (https://ibb.co/8XHRHpC)
https://i.ibb.co/NFhTWFq/image.jpg (https://ibb.co/kGnmqGT)
https://i.ibb.co/xKZLYm1/tenorite.jpg (https://ibb.co/cKq3wb6)
https://i.ibb.co/f8HfMfM/magnetiteblack.jpg (https://ibb.co/HNq6767)
https://i.ibb.co/X34S7RS/IMG-5409.jpg (https://ibb.co/SdxRtCR)
https://i.ibb.co/0JtjPNn/IMG-5410.jpg (https://ibb.co/ZTm6ysf)
https://i.ibb.co/y5999Fw/IMG-5411.jpg (https://ibb.co/d6TTT4d)
https://i.ibb.co/jyD7bFc/IMG-5412.jpg (https://ibb.co/5rLqGVN)
https://i.ibb.co/RpD0BWv/IMG-5413.jpg (https://ibb.co/PZ6h98m)

[Edd]

Epic

[jackosnovaturbo]

Time for some paint on the underside, I used jotun 80 I think I remember, which went on nicely, and found a couple of bits of rust on the "good" wings, so patched them up.

https://i.ibb.co/kQytVzM/IMG-5414.jpg (https://ibb.co/18nkYBb)


https://i.ibb.co/VY12xJt/IMG-5416.jpg (https://ibb.co/TMfm1Yk)


https://i.ibb.co/tqvcQMp/IMG-5415.jpg (https://ibb.co/bsCLQg5)


https://i.ibb.co/yR5DR02/IMG-5420.jpg (https://ibb.co/qn9znB6)


https://i.ibb.co/kqdSmXV/IMG-5421.jpg (https://ibb.co/6DdWXFc)


https://i.ibb.co/d4XG3z4/IMG-5422.jpg (https://ibb.co/yFKWMbF)


https://i.ibb.co/92ZTL74/IMG-5423.jpg (https://ibb.co/vmXPGSd)


https://i.ibb.co/wCjbmCt/IMG-5424.jpg (https://ibb.co/Y8wKs8g)


https://i.ibb.co/vj7xvYz/IMG-5425.jpg (https://ibb.co/z4yhHJf)


https://i.ibb.co/FxFss42/IMG-5429.jpg (https://ibb.co/ZL0HHz5)


https://i.ibb.co/rfrtpcK/IMG-5430.jpg (https://ibb.co/5xH9jnX)


https://i.ibb.co/wQh8T23/IMG-5431.jpg (https://ibb.co/ykFKDxG)

[jackosnovaturbo]

Epoxy primer for the bodywork after treating the bare metal with vinegar! and neutralized with water



https://i.ibb.co/zfc7Vng/IMG-5448.jpg
https://i.ibb.co/Vpv4qb7/IMG-5452.jpg
https://i.ibb.co/nM1vPb3/IMG-5455.jpg
https://i.ibb.co/tZGnQBv/IMG-5456.jpg
https://i.ibb.co/kDDdcvc/IMG-5457.jpg
https://i.ibb.co/bvNS5QF/IMG-5459.jpg
https://i.ibb.co/CBNS4R6/IMG-5460.jpg
https://i.ibb.co/26kDbkL/IMG-5465.jpg
https://i.ibb.co/SmfwpTz/IMG-5466.jpg
https://i.ibb.co/2ctPX9z/IMG-5467.jpg
https://i.ibb.co/2qjf719/IMG-5468.jpg
https://i.ibb.co/30V8pyk/IMG-5469.jpg
https://i.ibb.co/0Z7QpKD/IMG-5470.jpg
https://i.ibb.co/j356dVg/IMG-5471.jpg

[jackosnovaturbo]

A bit of bodywork.

https://i.ibb.co/fNmQkkS/IMG-5472.jpg
https://i.ibb.co/B22m8F1/IMG-5477.jpg
https://i.ibb.co/VtSCFxR/IMG-5478.jpg
https://i.ibb.co/SwSdP2r/IMG-5479.jpg
https://i.ibb.co/NpVCcNf/IMG-5480.jpg
https://i.ibb.co/2jjp5Jy/IMG-5481.jpg
https://i.ibb.co/dWQ4JYL/IMG-5484.jpg
https://i.ibb.co/fH6brtH/IMG-5488.jpg
https://i.ibb.co/tHx8CjP/IMG-5489.jpg
https://i.ibb.co/grdCXr0/IMG-5492.jpg
https://i.ibb.co/jZtWrvr/IMG-5493.jpg
https://i.ibb.co/sbWPtnF/IMG-5494.jpg
https://i.ibb.co/f0hZxRW/IMG-5495.jpg
https://i.ibb.co/YWjdpCH/IMG-6083.jpg
https://i.ibb.co/gW02Y8b/IMG-5496.jpg

[jackosnovaturbo]

Interior painted. The colour is Mercedes tenorite grey

https://i.ibb.co/fNmQkkS/IMG-5472.jpg
https://i.ibb.co/Yp1HGKH/IMG-5499.jpg



https://i.ibb.co/HpDDtL6/IMG-5503.jpg
https://i.ibb.co/55QZGp7/IMG-5504.jpg
https://i.ibb.co/mHJFFJR/IMG-5505.jpg
https://i.ibb.co/Jtp0cfb/IMG-6091.jpg
https://i.ibb.co/grYzJkB/IMG-6093.jpg


https://i.ibb.co/D4qPptz/IMG-6095.jpg

[jackosnovaturbo]

Test fit engine and make some mounts

https://i.ibb.co/vPR36dr/IMG-5512.jpg
https://i.ibb.co/XWP7P6V/IMG-5513.jpg
https://i.ibb.co/dgDCcT2/IMG-5514.jpg
https://i.ibb.co/vHn6Jc6/IMG-5517.jpg
https://i.ibb.co/WKdwg01/IMG-5516.jpg
https://i.ibb.co/wd9tRk9/IMG-5515.jpg
https://i.ibb.co/P5nwfyD/IMG-5518.jpg
https://i.ibb.co/pb4fsny/IMG-5520.jpg
https://i.ibb.co/M5vC7Px/IMG-5521.jpg
https://i.ibb.co/q7LpQ6X/IMG-5522.jpg
https://i.ibb.co/WPf9qjV/IMG-5523.jpg
https://i.ibb.co/SnRfvR2/IMG-5524.jpg
https://i.ibb.co/cv4XVsM/IMG-5525.jpg
https://i.ibb.co/TMp7DYm/IMG-5542.jpg

[jackosnovaturbo]

Underside painted


https://i.ibb.co/fNmQkkS/IMG-5472.jpg
https://i.ibb.co/NtTRjmq/IMG-5535.jpg
https://i.ibb.co/B2NkpPP/IMG-5536.jpg
https://i.ibb.co/yXPbyhT/IMG-5537.jpg
https://i.ibb.co/P9K2B81/IMG-5539.jpg
https://i.ibb.co/fYtX2Wm/IMG-5540.jpg
https://i.ibb.co/GQ8ZGyj/IMG-5541.jpg
https://i.ibb.co/YjvphpD/IMG-5544.jpg
https://i.ibb.co/92G2nkJ/IMG-5545.jpg
https://i.ibb.co/WVwvL9x/IMG-5546.jpg
https://i.ibb.co/jwpz9Rb/IMG-5547.jpg
https://i.ibb.co/9WP2sJT/IMG-5548.jpg
https://i.ibb.co/8DqcZgf/IMG-5549.jpg
https://i.ibb.co/GtmG62X/IMG-5552.jpg
https://i.ibb.co/SsNc63k/IMG-5551.jpg

[jackosnovaturbo]

Almost done with that


https://i.ibb.co/wBWsbf3/IMG-5554.jpg
https://i.ibb.co/tshp1D2/IMG-5556.jpg
https://i.ibb.co/5FpL6Ly/IMG-5557.jpg
https://i.ibb.co/0ZVL72Q/IMG-5558.jpg
https://i.ibb.co/MhrfyYD/IMG-5559.jpg
https://i.ibb.co/FbMyqYF/IMG-5560.jpg
https://i.ibb.co/Y3xgpZh/IMG-5570.jpg
https://i.ibb.co/F7zB6Zk/IMG-5569.jpg
https://i.ibb.co/GxvVhSy/IMG-5568.jpg
https://i.ibb.co/Y307wz2/IMG-5571.jpg
https://i.ibb.co/k9NFDf7/IMG-5575.jpg
https://i.ibb.co/1zn5Vz2/IMG-5574.jpg

[jackosnovaturbo]

Shell painted

https://i.ibb.co/8NcKSm9/IMG-5607.jpg


https://i.ibb.co/6XxLG3Y/IMG-5640.jpg


https://i.ibb.co/rMFBy5t/IMG-5642.jpg


https://i.ibb.co/L9dMnDB/IMG-5641.jpg


https://i.ibb.co/KNc3gRJ/IMG-5645.jpg


https://i.ibb.co/6WvHd3S/IMG-5647.jpg


https://i.ibb.co/NL5DQ8q/IMG-5649.jpg


https://i.ibb.co/4pSyJrd/IMG-5650.jpg


https://i.ibb.co/YW4MBQN/IMG-5651.jpg


https://i.ibb.co/Mcpx9WQ/IMG-5652.jpg


https://i.ibb.co/Vx9bFc8/IMG-5653.jpg


https://i.ibb.co/Ptbn7LB/IMG-5655.jpg


https://i.ibb.co/nnf6jmM/IMG-5656.jpg

[SRsam]

Mint work mate . Fabrication work is great too. Look forward to seeing more on it.

[jackosnovaturbo]

https://i.ibb.co/wsvRkRP/IMG-5688.jpg
https://i.ibb.co/TczD0kg/IMG-5706.jpg
https://i.ibb.co/D72QxJq/IMG-5727.jpg
https://i.ibb.co/Bwp7vFy/IMG-5728.jpg
https://i.ibb.co/vsZvWb4/IMG-5729.jpg
https://i.ibb.co/6Wfgf3k/IMG-5732.jpg
https://i.ibb.co/wrvw2NY/IMG-5731.jpg
https://i.ibb.co/zNVNZsZ/IMG-5689.jpg
https://i.ibb.co/cX9LBW4/IMG-5725.jpg
https://i.ibb.co/3rZrTvv/IMG-5750.jpg
https://i.ibb.co/2Fh4z5M/IMG-5734.jpg
https://i.ibb.co/zb2pKnS/IMG-5739.jpg
https://i.ibb.co/WD1JZGz/IMG-5742.jpg
https://i.ibb.co/SJxwhBP/IMG-5745.jpg

[jackosnovaturbo]

https://i.ibb.co/z7bxPrp/IMG-5752.jpg
https://i.ibb.co/MND1bbK/IMG-5761.jpg
https://i.ibb.co/2PhsLC3/IMG-5766.jpg
https://i.ibb.co/M1kZrzm/IMG-5781.jpg
https://i.ibb.co/MgFMvBb/IMG-5782.jpg
https://i.ibb.co/SVFqgJj/IMG-20151201-134633.jpg
https://i.ibb.co/BPZKJbv/IMG-20151201-134639.jpg
https://i.ibb.co/HKgJRmv/IMG-20151201-134710.jpg
https://i.ibb.co/PY2VB2h/IMG-20151201-134740.jpg
https://i.ibb.co/0j1jvNw/IMG-20151201-134721.jpg
https://i.ibb.co/R7C41LR/IMG-20151201-134753.jpg
https://i.ibb.co/Yj0fWYC/IMG-20151201-141121.jpg

[jackosnovaturbo]

This was 2016 fitted epas, interior, wiring and has not had much done until recently

https://i.ibb.co/CJM9S2W/IMG-20151204-130432.jpg
https://i.ibb.co/Lpz6HHW/IMG-20151204-195829.jpg
https://i.ibb.co/WHzFM1k/IMG-20151204-195834.jpg
https://i.ibb.co/Fwckfhn/IMG-20151204-201326.jpg
https://i.ibb.co/TBJzhJT/IMG-20151204-201423.jpg
https://i.ibb.co/cc3JPhs/IMG-20151206-143347.jpg
https://i.ibb.co/3h4FGkR/IMG-20151206-151806.jpg
https://i.ibb.co/YQ3tcC8/IMG-20151206-151835.jpg
https://i.ibb.co/0QjrSZs/IMG-20151216-141937.jpg
https://i.ibb.co/HCq4M8Y/IMG-20151216-141905.jpg
https://i.ibb.co/QrrDFCb/IMG-20151223-140420.jpg
https://i.ibb.co/P4nSh8R/IMG-20160205-163106.jpg
https://i.ibb.co/Q8jsy4C/IMG-20160316-211726.jpg
https://i.ibb.co/fHP35Pc/IMG-20160710-124758.jpg

[rickygolf83]

Nice work man!

Getting there now

Sent from my SM-G950F using Tapatalk

[torquey]

Awsome work looks great

[C16xe]

Fairplay to you mate you don't hang about do you :eek:

[totalnova]

Car looks immaculate, really good work, there are some top cars being turned out recently.

[jackosnovaturbo]

Thanks for the positive comments guys! It's not something I would want to repeat in a hurry.

I have recently started with the engine work so hopefully I will have it finished before 2020!

Time to start making some manifolds.

BW 6758 turbo
https://i.ibb.co/wYkgDmv/image.jpg (https://ibb.co/g629sKn)

https://i.ibb.co/t41pNmB/image.jpg (https://ibb.co/jTjkx6h)

https://i.ibb.co/rZk9sbR/image.jpg (https://ibb.co/7Gvh4gd)

https://i.ibb.co/0KPzMng/image.jpg (https://ibb.co/8bFQ5mW)

https://i.ibb.co/j8xTZZs/image.jpg (https://ibb.co/WHd6ppj)

https://i.ibb.co/nmFyQgg/image.jpg (https://ibb.co/qjv8myy)

https://i.ibb.co/bg910yL/image.jpg (https://ibb.co/8DZMCR2)

https://i.ibb.co/C7GVpSk/image.jpg (https://ibb.co/SnCVDZh)

https://i.ibb.co/44hwLwG/image.jpg (https://ibb.co/9yQm0mL)

https://i.ibb.co/Ln5Knht/image.jpg (https://ibb.co/jgRtgZM)

https://i.ibb.co/HHHBNwz/image.jpg (https://ibb.co/711jgMW)

I did not want a removable slam panel so there is nothing available to buy for a Nova that remotely fits. This can be removed with the engine in situ and the oil drain is still in a good place and the radiator is not hanging out of the front of the car.

https://i.ibb.co/HqCKGN9/image.jpg (https://ibb.co/sqCgs5X)

[boffer8]

Looking good!

Where did you get the bends and the collector from? Looks nice!

[jackosnovaturbo]

Looking good!

Where did you get the bends and the collector from? Looks nice!

Bends were 40sch 1 1/4 inch from nero pipe http://www.nero.co.uk

Collector from ebay

https://www.ebay.co.uk/itm/Hypertune-HypEX-Investment-Cast-Stainless-Steel-V-band-Manifold-Collector-1-25/322314638197?hash=item4b0b731375:g:U7MAAOSwFe5XyTd y:rk:1:pf:0

And the best quality flange I realised is actually from a standard c20xe manifold, although it was a real pain to remove the old pipes from the inside of the flange with a die grinder.

[Panman]

This is great. Nice build.

[ben doodar]

Absoloutle epic work the most intense nova project I've seen. How long has the project taken you? Do you do this kind of work for a living?

[jackosnovaturbo]

Absoloutle epic work the most intense nova project I've seen. How long has the project taken you? Do you do this kind of work for a living?


Well I have done tig welding as a job, carbon fiber, and a little car bodywork as jobs. It's more just accumulation of skills and knowledge really, I've been doing restorations on Nova's for quite a few years but never anything like this.

There has been some progress but I've been busy with cycling so it's going slowly.

Inlet manifold build:



Initial fit up, cut flange from old xe mani, found right diameter pipe, a piece of 8mm scrap stock I had lying around, 10mm backing plate radius by die grinder, plenum cover ex -gtir. total cost around £50

https://i.ibb.co/HGCBWn8/IMG-9966.jpg
https://i.ibb.co/WpPBC26/IMG-9965.jpg
https://i.ibb.co/qYCX4yS/IMG-9967.jpg
https://i.ibb.co/gZwVtfj/IMG-9968.jpg
https://i.ibb.co/HDCD1TR/IMG-9973.jpg
https://i.ibb.co/GCgdvvf/IMG-9969.jpg
https://i.ibb.co/kSN5dh2/IMG-9977.jpg

https://i.ibb.co/hWgqT6Q/IMG-9979.jpg

I was gonna trumpet the inlet but after some reseach and realising how good of a radius I could get from the thick backing plate decided it was not worth the hassle or potential gain.

The welding turned out not to be the neatest due to 220amp maximum on my machine and if I were to do it again I would not use the GTiR inlet as used cast aluminium engine parts poses some contamination issues when welded. However, I have been carting that thing around with me since 2005 so I was determined to use it.:cry:lol

[jackosnovaturbo]

More progress, inlet all welded with flange for cav v6 TB

https://i.ibb.co/n3pTyvs/IMG-1242-1.jpg
https://i.ibb.co/RcFtLZD/IMG-1246.jpg
https://i.ibb.co/GxCBPyF/IMG-1296.jpg
https://i.ibb.co/8xS8yXz/IMG-1297.jpg
https://i.ibb.co/YBtdcbQ/IMG-1298.jpg

Anyone got a cav V6 cable for sale?

[jackosnovaturbo]

Some more progess,

Exhaust manifold all welded up, what an absolute pain in the arse backpurging it all, gapping all the pipes with a 3mm gap, welded with a keyhole backfeed technique on the root pass, then filler pass and hot cap.
https://i.ibb.co/D49WnQ0/IMG-1299.jpg
https://i.ibb.co/ckHGMCm/IMG-1243-1.jpg
https://i.ibb.co/nRygGFH/IMG-1293.jpg
https://i.ibb.co/Jn9HNtB/IMG-1292.jpg
https://i.ibb.co/1qmTH5P/IMG-1285.jpg
https://i.ibb.co/C0Ghv5T/IMG-1289.jpg
https://i.ibb.co/2nxBzfh/IMG-1258.jpg

Exhaust downpipe 3" with wastegate routed back in under sump, I might add a flexi on the wg pipe.

[total_vauxhall]

Make sure you use heavy duty mounts for your fuel rail pal i have built a similar inlet for mine . I welded 5mm plate tabs on thinking they would hold the rail . Seems they didnt like 60psi of fuel and bent like twigs at the weekend racing ending in fuel everywhere. Im now on welding solid blocks on like the standard manifolfd has .

Nice build by the way glad to see someone else building manifolds rather than buying off the shelf .

I think sri cable will fit aswellhttps://uploads.tapatalk-cdn.com/20190806/009fd0a6949b604b958474f9bc3bcc9c.jpghttps://uploads.tapatalk-cdn.com/20190806/4a330db5bd481190df196b2133be0c5b.jpg

Sent from my CLT-L29 using Tapatalk

[jackosnovaturbo]

Yeah, thanks for the heads up! The other day I already remembered a number of problems back in the day with people using the thin SBD fuel rails and they were bending. I've got a billet fuel rail blank coming and I think, with short injectors it will bolt from the plenum behind kinda jamming it in. The last thing you need if fuel pissing out all over your red hot motor!

[total_vauxhall]

Yea especially when its methanol lol

[jackosnovaturbo]

I just looked at you build thread, looks mental, I'm from Middlesbrough originally, my Mam still lives in Redcar, your neck of the woods. I think I might copy you and go for the black wrinkle paint finish on the inlet and boost pipes when it's done, i'm not a fan of shiny engine bays it's a bit 90's max power ?!

[total_vauxhall]

Ahh thats strange lol yea i only live 5 miles from redcar . And yea my last engine bay set up at start of the year was very shiney . Not purposely just because of all the new parts i had bought but im much happier now with it all dulled down and the wrinkle paint makes the finish look much more professional. Did you have novas when you were round this way ?

[Benn]

Wow!

Hell of a build, love that you cut the front off and replaced.
You've got the cleanest chassis legs I've ever seen.

Any more EPA's fitting photos?

[scott.parker]

Any updates on this, amazing build, well done.

[jackosnovaturbo]

big update coming soon