View Full Version : ADES GARAGE V2! **now with pics! **
aye - was thinking about additional welds on the back to tbh I'm happy with it as is. I'll be getting meself a few tins or red oxide and zinc primer on Wednesday when I get paid.
Oh and phoned machine mart - they reckon the regulator was on too tight but offered to exchange the canisters if still not working
mikey14sr
21-01-08, 09:56 PM
Their argon/co2 mix bottles are known for having deeper-set pins in the top which leads to having to almost force the regulator to open more than it should to get a good flow of gas. I've had problems with it before myself. The guys behind the counter will deny any knowledge of it though.
Also even the high-capacity bottles only tend to last for around 1 meter of continuous welding, do a few stop-start welds, and add in the gas wasted before and after the arc has struck, time-wise thats about an hour per bottle.
Plenty of seam-sealer once the rust-proofing coats have dried on the back to keep the dirt and moisture out too;) .
DW-Nova
21-01-08, 11:49 PM
Looking very good mate, the welds on the wings look excellent, especially for a first attempt! they'll be more than strong enough to tack the wings together, once theyr'e skimmed with filler it'll be looking sweet, what's next then? did you say new rear arches? are you going to go wide arch or stay standard? i reckon the SID wide arch kit would suit this but it's obviously upto you, your going to be making your own bodykit out of foam and fibreglass arnt you? absolutley loving this car mate, it's just so different, what you gonna do with the back end of the car then? your gonna have to do something weird hey. Look forward to seeing your next update.
Matt2107
22-01-08, 01:36 PM
Nice work as always Ade.
You should be proud.
cheers for the comment guys! I'll be replacing the rear arches and at least the passenger side sill. Mikey - I've found stop/start welds are the best - If I try and do a long weld I just blow holes - with stop/start welds I can also check where I'm welding so I dont wander! lol
I'll be making my own body kit (front/rear bumper, grill (blended into bumper)) and side skirts as well as a smoothed rear boot with a VW custom boot latch (with a vaux badge)...
Wednesday 23/01/2008
Had a day off today (although got to work this weekend which is a bummer) so thought I'd tackle the underside part of the wings - the bit that sits under the lights.
The existing Nova wings had a section that bent round and clipped into the grill to complete the small edge before the bumper. I'm wanting to do something similar but obviously need to fabricate a new section to follow the contour of the Punto lights.
I started off working out how the bumper would be bolted at the front and then how the bumper (with grill built in) would connect to the wing.
I'll basically run a skirt of metal along the underside of the lights following the contour of the light. This will have holes drilled in it so clips can be clipped onto it allowing the wings and bumper/grill to be screwer in place. It'll be fiddley but will be nice and tight.
Once that was sorted in my mind I started by making a card template -
http://img.photobucket.com/albums/v13/danga/wingbottom0002.jpg
http://img.photobucket.com/albums/v13/danga/wingbottom0005.jpg
http://img.photobucket.com/albums/v13/danga/wingbottom0001.jpg
This will need to be welded to the existing extension at the bottom corner of the wing as well as the underside for additional strength.
The new section will have a contoured lip running along the top edge to add detail (which will be along the bottom of the lights) and this will follow around and tuck back in for a flush finish.
Once the template was made I took it apart and then cut out the necessary parts, leaving enough metal to form flaps making joining the parts easier -
http://img.photobucket.com/albums/v13/danga/wingbottom0006.jpg
http://img.photobucket.com/albums/v13/danga/wingbottom0007.jpg
http://img.photobucket.com/albums/v13/danga/wingbottom0008.jpg
At the moment the end that joins on to the bottom of the new extension (bottom corner of the lights) sits on top so I had to trim this back. I then joggled the edge of the new extension so the new part would sit flush on top. This was then welded in place. Once this was tacked in place I tacked the underside checking the clearences along the front of the lights in case the new part fouled on the bottom of the lights (which it didnt).
I then welded it up - which proved pretty difficult. I blew a couple fo holes in places which had to be repaired.
However by the end of the day I managed to complete one side -
http://img.photobucket.com/albums/v13/danga/wingbottom0010.jpg
http://img.photobucket.com/albums/v13/danga/wingbottom0012.jpg
http://img.photobucket.com/albums/v13/danga/wingbottom0013.jpg
http://img.photobucket.com/albums/v13/danga/wingbottom0015.jpg
I'm really pleased with the outcome. I need to clean up the welds on the underside however this wont take long. The area where it joined the new extension needs a bit more work however most of this area will be under a skim of filler.
You can see how the new part follows the line of the lights and theres a nice line that can be drawn from the bonnet down - this will be followed into the design of the front bumper and should follow the ange of the grill.
The whole area will be getting a skim of filler to remove any imperfections.
I'll probably do the other one tomrrow night.
your attention to detail is crazy ade
DW-Nova
24-01-08, 08:20 PM
Brilliant work yet again mate, may i suggest that you invest in a light reactive welding mask though, they make everything alot easier as you can see through the mask just like a lightly tinted window before you start welding, then as soon as it lights up it changes darker so as not to blind you.
mikey14sr
24-01-08, 08:29 PM
Sounds like you could do with a little less power or a bit more wire speed if you're still blowing through, thin stuff like this can be a real pain to find the right set-up for.
Once again though, excellent bit of tin-bashing there! and a good idea to aim to get the joints slightly lower than the finished level.
An auto helmet would probably be a good idea, I know I could have done with one on more than enough occasions when weldng nova's! I have used one before, when they first started showing up (were around ?250!), an absolute god-send when welding upside-down!
i couldnt weldwith out 1 now
Tuesday 29/01/2008
Another day off work (was working the weekend just gone) so spent all day in the garage with the welder working on my wings.
Spent most of the day fabricating the underside to seal up the gaps after I cut and bent the bracket that the old grill used to clip into. This is now the underside of my extension. Then spent a while grinding back some of the welds and then fill welding to level some areas off.
Got a tad c0cky and although welded most of the time with my mask on - did a few with eyes closed really tight/looking away (mostly spot welds). However this is not recommended - why? because you can forget to close your eyes and blind yourself (which I didnt) but something I forgot is that the ultraviolet radiation given off basically gives you sun burn!
So now I have a red face except for the area where the top of my welding mask sat on my head where I have a nice perfectly straight white line!
lol
I'll post pics of the wings tomorrow...in the meantime I'm off the apply some after sun!
Need pics of the tan..
youre only a real man when you weld upside down with just a tee shirt on ;)
i had some spatter go down my jeans onces.. had a bold patch pmsl...
mikey14sr
31-01-08, 10:05 AM
lol, that's why I used to weld in a t-shirt, kept the tan topped up! Wait till you've experienced a blob of hot, molten metal dropping into you're ear, I tell you that fecking hurts! (not too nice when it burns through your jeans and heads for the old tackle either!)
i had a few bits go down my gauntlets.. i dotn think ive seen one fly across the workshop so fast
still after punto wings? may know of some knackered ones i can cut the top corner off and post
still after punto wings? may know of some knackered ones i can cut the top corner off and post
cheers but dont need them now.
Friday 01/02/2008
Tan faded pretty quickly but now I look like a fecking radiation victim with the skin on my nose cheeks, forehead and chin peeling! Looks like I have some kind or dodgy skin disorder!
Made an excuse and left work early to apply some "lotion". Actually been feeling a little sh1tey for the last couple of days - sort of fatigued...probably not linked.
Anyway - after a short "rest" (couple of hours kip) I went back into the garage and cleaned up some of the welds. Fitted both wings and checked the gaps along the bonnet which considering I still need to clean them up and finish the bonnet off were pretty damn good!
Gave the new sections a coat of etch primer ready for a layer of filler on Saturday. I can now start to apply some detail.
just vaux trev
01-02-08, 11:36 PM
lol, that's why I used to weld in a t-shirt, kept the tan topped up! Wait till you've experienced a blob of hot, molten metal dropping into you're ear, I tell you that fecking hurts! (not too nice when it burns through your jeans and heads for the old tackle either!)
i had the same in the ear while welding a new floor in a mates transit:eek:
looking good ade cant wait see some more areas tackled:thumb:
Sunday 03/02/2008
Today I wanted to get a skim of filler on the wings to at least build up the right levles ready for more detail. i also set myself the task of cleaning up the slam panel which is currently bugging me because its made up of about 10 different parts of metal all rivitted togetehr. The idea is to create a continous smooth panel that's welded in place. This will add strength to the rivetted sections and make it look much neater.
I started with the wings and after lining them up I bolted them in place. I then gave them both a couple of skims of filler. this looks really rough at the moment but the idea is to build up several layers and then cut it back to get the profiles I need.
Whilst this was drying I made a card template for the slam panel. Because the sheet steel I'm using isnt wide enough I'll be making it in 2 sections and joining it in the middle.
Once the card template was made I marked up and cut out the parts. I had to grind these out as my tin snips werent up to the job (only 1mm steel!) These parts then had to be bent into shape to fit. before welding in place I had to remove the paint I'd applied initially. This took ages.
I managed to get the passenger side welded in place and most opf the welds ground back before I packed up.
I'll get some pics up the next day or so - my memory cards are currently full of horse pics from a lesson the wife had the other week - need to get my ar$e in gear and download them!
mikey14sr
03-02-08, 11:24 PM
The ill feeling was probably from the welding fumes Ade, make sure you've plenty of ventilation, and maybe wear a paper partical mask.
usually wear my paint spray mask when welding / grinding - I think the last few days I've had man flu - my heads buzzing, eyes are sore and I keep sneezing snot everywhere!
Wife has no sympathy.
nov4801
10-02-08, 04:42 AM
looking good mate, not looked at this thread since you was working on sorting the lights out, page 13.didnt read every post but still took 2+hours to get through it and was worth every minute. looks ****ing awsome mate and cant wait to see it finished, the front bumper i would go with the original design you put on paper. any news on when she will be done and whats the first show you going to as i will have to take the weekend off work to come see it. keep up the awsome work mate.
scott
chers matey - I'm aiming for Billing or Trax - Sept time...that'll be the external stuff anyway...I hope!
nov4801
10-02-08, 06:19 PM
ok mate, will book them weekends off work lol, :thumb:
Saturday 09/02/2008
Well - been sufering with a right evil cold all week - evil snot, sore eyes, coughing, sneezing and a brain that felt like I had a head full of cotton wool. Also worked back shift all week so felt 10 times worse!
Anyway - set by alarm for 8am Saturday morning and forced myself into the garage 1st thing!
Started by finishing off welding the additional panel I'd made to the top of the slam panel. Went round all the edges and then ground back the excess. Now both panels are joined they give the top front section a pretty smooth finish. It still needs some work - more tidying up than anything else but it looks much better than the other rivitted bits and it adds more strength to the whole front section...(at this point I curse myself for not learning to weld when I did the rivetted sections!)
(before it was fully cleaned up -front looks a tad uneven)
http://img.photobucket.com/albums/v13/danga/wingfil0010.jpg
I then started cleaning up the wing extensions. I needed to sand back the 1st layer of filler I'd applied earlier in the week to get the basic shape then build it up further so it was flush with the original wing, following the new curve at the front. Here's a wip...
http://img.photobucket.com/albums/v13/danga/wingfil0002.jpg
http://img.photobucket.com/albums/v13/danga/wingfil0009.jpg
http://img.photobucket.com/albums/v13/danga/wingfil0007.jpg
As you can see from the last pic the top curve doesnt match the bonnet curve and between the lights and the bottom of the curve theres a small gap. It's only about 4mm so nothing a bit of filler wont sort out easily enough.
Next stage was to refit the lights and then skim the edges of the lights to where they wings butt up to them. I also skimmed the top curve to match the underside of the bonnet. Just before the filler totally cures I trimmed about a 5mm gap round the edges (except for the top) - this sounds like a lot but allows for light unit adjustments. The actual additional material once the gap had been removed was minimal which I'm pleased about as it means 95% of the extension is metal! Once set I then removed the wings and tidied up the inside edges, smoothing the excess filler back and blending it into the wing from the inside. this will be totally sealed with underseal once finally painted for added protection.
http://img.photobucket.com/albums/v13/danga/wingfil0018.jpg
http://img.photobucket.com/albums/v13/danga/wingfil0022.jpg
http://img.photobucket.com/albums/v13/danga/wingfil0020.jpg
http://img.photobucket.com/albums/v13/danga/wingfil0019.jpg
Called it a night at this stage...
keep poping back to watch this thread mate! looks like its comeing along nicely! doing a top job getting those lisgts to fit factory!
chimp007_uk
10-02-08, 09:47 PM
looking awesome as usual... where do you get your patience from?
Sunday 10/02/2008
Didnt have too long in the garage today as the wife wanted me to photograph her jumping her horse! Spent most of the morning cleaning up the wing extensions I'd skimmed the night before.
After much sanding I gave them a quick coat of primer to get a look at how they were coming along.
http://img.photobucket.com/albums/v13/danga/wingfil0031.jpg
http://img.photobucket.com/albums/v13/danga/wingfil0027.jpg
http://img.photobucket.com/albums/v13/danga/wingfil0032.jpg
http://img.photobucket.com/albums/v13/danga/wingfil0033.jpg
http://img.photobucket.com/albums/v13/danga/wingfil0034.jpg
The next task is to tidy up the lines. I need to extend the classic nova arch bit that sticks out on the wings as well as the line that runs the length of the car. The last bit is to make a straight line that the bumper will butt up against at the bottom of the wing...
I then left the wings whilst the primer was curing and started work on the bumper...began by making a template for the underside of the lights - I figured I'd start from the top and work downwards so started by making the section that sits directly under the lights and grill. After I'd made a card template for one side I flipped it over and was chuffed to see that the reversed side was an exact fit! At least I now know my wings and lights are set up properly!
before I had chance to start hacking up chuumky of polyeutherene foam sheet it was 2pm so had to shut up shop! Just getting going as well...
:roll:
looking awesome as usual... where do you get your patience from?
lol - ar$ing about in me garage is my patience time. Jobs mental and I find I can really unwind in the garage...
I am the typical man - I love my space - and the garage fulfills (nearly) all my needs...
lol
http://img.photobucket.com/albums/v13/danga/wingfil0032.jpg
OMFG!
i efffin love it ade
Clarky_15
12-02-08, 12:25 AM
Nice read and the car is outstanding!
vaughanmc
15-02-08, 06:22 PM
Top work mate - Can't wait to see it done :)
Friday 15/02/2008
Off work today (working this weekend though :mad:) so I thought I'd get the base of the bumper sorted out.
I actually started some template stuff earlier in the week but was having a brain dead moment over how the grill sits. On the New style Astra the bottom of the V sits flush on the top of the bumper with the clips on the bottom of the grill clipping into the back of the bumper - which are hidden by a slightly raised bit. However I couldnt replicate this in mine because the grill sits a bit lower so I wasted ages trying to work it all out. In the end I decided to cut a notch out for the V until I got the basic shape of the bumper sorted out then I can go back and work on it in more detail...
So - the 1st task was to make the top section of the bumper. The rest of the bumper will drop down from this (much easier that way). I'm using non resin reacting foam board to form the basic shape.
http://img.photobucket.com/albums/v13/danga/bumper0102.jpg
http://img.photobucket.com/albums/v13/danga/bumper0103.jpg
http://img.photobucket.com/albums/v13/danga/bumper0100.jpg
This is a very rough outline - the main objective is to get the underside sorted, work out where the holes for will line up with the grill and ensure the curve of the lights and the top of the bumper are even.
This took a while to do...
The next step was to build down. I took some measurements from a standard GSi grill and added a further 5cm (which would represent an standard splitter) to get the depth right. I decided to bond large 20cm x 30cm foam board sections to the underside of the top section.
These are 5cm thick and will form the base of the bumper from which everything else is built on to (or carved in to).
http://img.photobucket.com/albums/v13/danga/bumper0106.jpg
http://img.photobucket.com/albums/v13/danga/bumper0108.jpg
http://img.photobucket.com/albums/v13/danga/bumper0105.jpg
http://img.photobucket.com/albums/v13/danga/bumper0111.jpg
These images show a very rough base but give you the basic idea.
Once its smoothed back I will make a base section which will run the entire length of the bumper (for strength).
Before I can do this though I need to add the sides.
And before I can do that I needed to ensure I had a flush line on my wings.
After applying a skim of filler and whilst I waited for it to dry I smoothed the lines on the bumper front down to give a smoothish base to work from.
nice1 mate, did them pics from Mr Samples help you?
certainly did. I'll most likely take the bits either side of the V right down - like an inverted curve.
NOV4_SPORT
16-02-08, 09:38 AM
this thread never fails to amaze me, the work and detail your putting into the project is amazing, it reminds me a lot of "joff's" twin dash turbo beast, keep up the hard work and i hope to see it over the summer.
iain
Sunday 17/02/2008
Working again today but finished at 2 so by the time I got hime (3.30) I skipped into the garage to finish off the base of the front bumper...
I started by cleaning up the sides of the wings so there was a smooth line from which to line up the bumper sides.
I then cut out sections of foam and bonded them onto the rest of the bumper I started the other day. After some rough shaping the bumper started to take on a "bumper" feel -
http://img.photobucket.com/albums/v13/danga/bumper0155.jpg
http://img.photobucket.com/albums/v13/danga/bumper0156.jpg
http://img.photobucket.com/albums/v13/danga/bumper0157.jpg
http://img.photobucket.com/albums/v13/danga/bumper0153.jpg
http://img.photobucket.com/albums/v13/danga/bumper0154.jpg
The next task was to ensure the depth of the bumper was correct.
Your standard GSi bumper is about 35cm deep from lights to underside. Add on a 5cm splitter and your'e talking your standard modded Nova bumper depth. So in theory the bumper should be about 40cm deep.
I needed to confirm this and had a dead brain moment again for a bit as I tried to work out the current ride height of my car in relation to the base of the bumper and the ground - obviously without an engine everything is considerably higher. I remembered that with my engine in and my 60mm suspension drop the distance between the top of my wheels and arch was literally about 2cm so afetr messing with a tape measure and lining up the foam bumper with the existing GSoi bumper I had I wasted probably 30 mins just to come to the conclusions I needed 5cm - basically the original quick workings I'd made
D'OH!
The foam board I'm using is 5cm thick which is convenient so the next task was to make a template for the base of the bumper and cut out some foam strips which would help strengthen the bottom of the bumper, line up the curves and give it the depth I wanted.
Heres the result -
http://img.photobucket.com/albums/v13/danga/bumper0159.jpg
http://img.photobucket.com/albums/v13/danga/bumper0158.jpg
http://img.photobucket.com/albums/v13/danga/bumper0160.jpg
As you can see it's got a much bigger presence.
oops posted same thing twice
Sunday 17/02/2008 continued...
The next task (after I'd swept my dusty garage floor and removed all the foam cut off) was to smooth it a little and then rough out the basic look of the bumper...
Here's the original design I'd drafted several years ago (see page 7 of the thread) -
http://img.photobucket.com/albums/v13/danga/draftfront1.jpg
which is based on the OPC Corsa body kit (pre latest faceflift version) with a bit of the new style astra in for the grill section...
http://img.photobucket.com/albums/v13/danga/1537-1.jpg
Here's the quick draft layout I did before calling it a night. Note nothings really lined up properly yet...
http://img.photobucket.com/albums/v13/danga/bumper0162.jpg
http://img.photobucket.com/albums/v13/danga/bumper0163.jpg
http://img.photobucket.com/albums/v13/danga/bumper0164.jpg
http://img.photobucket.com/albums/v13/danga/bumper0165.jpg
The next task is to cut the bumper about and start to shape it...
Oh - and add the little corner bits on the sides I seem to have forgotten!
Lee-170
17-02-08, 10:01 PM
looking good ade cant wait to see it finished :thumb:
that look farking awesome Ade! Although I don't know if it the angle of the photo or something, but it kinda looks like its falling away from the car... Maybe a stronger line around the bottom of the grill and between the lights?
Maybe - dunno, could be alright... i'll get back to you lol
Actually if you dig the centre section of the bumper out like to opc corsa then I think it will solve it :)
it probably was falling away - its only held in place with 2 clamps at the side so the weight will have pulled the nose down slightly so under the V of the grill its probably about 1cm too low...
Ade
vaughanmc
17-02-08, 10:42 PM
Looks awsome that bumper - Will be good to see it with all the wee cut outs :)
Just P/S'd it - wanna see it ade, or wait till your done?
i may of allready asked this.. but will she be at pvs08?
mikeoxford
18-02-08, 01:46 AM
i just absolutely laughed out loud. i am totally amazed. if your models werent testament enough to your effort and detail, this certainly is!
well done ade :thumb:
theres a whole lotta pages to search through, and I don't recall any engine plans? is that top secret? lol
That front end looks absolutly quality ade !
I'm still slightly hesitant as to how it's all going to blend together (i.e the Roof/window lines ; as you can't really change them) But i'm sure it'l get there in the end !
I dont think I'll be there for PV show - although I'll probably turn up myself.
Pushing for VBOA but realistically I "may" have the external bits ready for Trax.
TBH the full car isnt going to be ready till next year....
Engine wise I'm keeping it standard - 1.6 GSi with cone filter. Hopefully will get it rebuilt. make it last...
annoyingly VBOA is the same weekend at T-in the park and I'm having probs getting time off work.
GRRR
Still very much a WIP ad, it was a quick attempt to start with:
http://img99.imageshack.us/img99/6141/adejj4.jpg (http://imageshack.us)
lee coley
20-02-08, 07:04 AM
nice 1 Ade.
yoza
dave.gsi
20-02-08, 02:31 PM
looking good mate, brings back memories of when i made a bumper for a uni project (must be 6 years ago now :eek: lol )
http://i192.photobucket.com/albums/z252/daveonearm/Picture127.jpg
http://i192.photobucket.com/albums/z252/daveonearm/Picture185.jpg
i know how much work went into making that, you're doing the whole car you nutter lol
Dave I remember seeing a thread on that bumper years ago!
lol
Ash that's pretty cool - the yellow burnt my eyes though! Make it more like more like custard yellow lol
pretty cool though!
Thursday 21/02/2008
Day off work today and after a visit to the dentist tat left me ?200 lighter in the wallet (only had 2 fillings and a feckin clean!) I ordered a few parts from my local Vauxhall garage and courtesy of Ali who works there (who also used to own a 2ltr nova until recently) got a nice discount!
:thumb:
orders bolts and a few connectors but also placed an order for an OPC opel Grill with a honeycombe section like this one -
http://www.madle.org/ms05sopel.jpg
The stripe that surrounds the badge I'll paint to match my cars colour - yellow or Anthracite - not sure yet...
Bit of a sin that It's gonna be "trimmed" down to fit me Nova but with the bottom section nice and smooth it will fit much nicer with my bumper.
Speaking of which I spent most of the afternoon shaping it.
Started by measuring and drawing the design then bonded on a layer of foam to bring the side panels out to the right depth -
http://img.photobucket.com/albums/v13/danga/bumperhole0001.jpg
http://img.photobucket.com/albums/v13/danga/bumperhole0003.jpg
http://img.photobucket.com/albums/v13/danga/bumperhole0002.jpg
I then smoothed these down so the top section blended in with the lines under the lights.
The next step was to cut the lower vent out -
http://img.photobucket.com/albums/v13/danga/bumperhole0004.jpg
http://img.photobucket.com/albums/v13/danga/bumperhole0007.jpg
The centre support isnt bonded inplace - just for show. It's now starting to feel like a bumper!
I then fettled, cut, bonded and sanded away until I had something that resembles a cross between an Astra bumper and an Audi!
The following pics show the bumper pretty much complete from a frontal perspective. I need to work out the position of the fog lights as well as add some more detail to the bottom (the centre section will be trimmed and rolled so it flows back) -
http://img.photobucket.com/albums/v13/danga/bumperhole0009.jpg
http://img.photobucket.com/albums/v13/danga/bumperhole0012.jpg
http://img.photobucket.com/albums/v13/danga/bumperhole0018.jpg
http://img.photobucket.com/albums/v13/danga/bumperhole0019.jpg
http://img.photobucket.com/albums/v13/danga/bumperhole0014.jpg
http://img.photobucket.com/albums/v13/danga/bumperhole0020.jpg
http://img.photobucket.com/albums/v13/danga/bumperhole0027.jpg
http://img.photobucket.com/albums/v13/danga/bumperhole0023.jpg
Heres one with the foam photoshopped in primer grey-
http://img.photobucket.com/albums/v13/danga/bumperhole0008pr.jpg
The only bit to add to the front is the 2 lower slats that sit on the corners of the lower vent mouth (there will be reflectors in these).
the sides still need finishing off too.
However I cant help thinking there's something missing. the sides seem too flat/dominant. I'll need to look at some kind of surround for the fogs...
Was thinking of Audi A3 lower fog light/vent slats (theres a paid on ebay just now) -
http://www.dandsauto.com/images/inventory/47/Audi%20A4.jpg
perhaps something like these (the slats and the fog surround mounted on a honeycombe back pattern perhaps)
Welsh Dan
21-02-08, 11:08 PM
Might I suggest moving the fogs outwards, adding some nice big driving/spotlamps, and headlight washers?
http://www.xen0phobiak.f2s.com/novaload/ade.jpg
Something like this?
http://i13.photobucket.com/albums/a266/razorjack/Cars/ade1.jpg
not bad - I'm thinking on similar lines -
Before -
http://img.photobucket.com/albums/v13/danga/bumperhole0019b.jpg
after -
http://img.photobucket.com/albums/v13/danga/bumperhole0019f.jpg
liking that ade. i like the way the spot lights match the projector bit of the headight
novarobbo
21-02-08, 11:48 PM
i think the fogs need to be out abit more they look to close together imo
yeah - agree - perhaps If they were centred in the fog surround - I'd probably recess them too...I actually have a spare set of the chrome light housings from a spare set of punto lights I could use! the above fog light pics are also to scale - my fogs are 6.5cm in diameter...
I may also take a small line from the top of the lower vent (bottom of the numper plate) and run it right round both sides. Also the sides need to tow in a bit...
novarobbo
22-02-08, 12:36 AM
think centred in the fog light surround/housing would get my vote..
looks good and im sure whatever you do will look ace along with the rest of the car.. it really is looking good.. give yourself a pat on the back :thumb:
dave.gsi
22-02-08, 10:37 PM
my 50p's worth.........
in this photo where you've added the extra foam to bring out the bumper ----->
http://img.photobucket.com/albums/v13/danga/bumperhole0002.jpg
i don't think its enough. maybe another layer on top (10mm or so) and it would really define the bumper side sections. once that is done you wouldn't have to add any fancy fog light covers, it would look cool just nice and plain :thumb:
vaughanmc
22-02-08, 11:14 PM
Looks awsome Ade, keep up the class work :)
shy witness
23-02-08, 06:10 PM
Something like this?
http://i13.photobucket.com/albums/a266/razorjack/Cars/ade1.jpg
i think that looks pretty decent there imo
:thumb:
mikey14sr
23-02-08, 06:32 PM
I may also take a small line from the top of the lower vent (bottom of the numper plate) and run it right round both sides. Also the sides need to tow in a bit...
Maybe add another 5/10mm thickness above the line and a bit of heavy shaving underneath it to put shape into the bottom half?
Thanks for the ideas guys. I've gone with a combination of mine and Jacks taking on board your points. See below the what I did!
Friday 22/02/2008
Took the day off work so I could crack on with my bumper. before I started I decided to order the OPC honeycombed panel that slots into the big mouth section of the Astra H's bumper. Will mod to fit mine so will be uniform from Grill to Bumper.
I started by thinking about the above changes to the fog light sections and came up with a design that's a combination of mine and Jacks idea - uses my height but with the wrap around raised section brings the entire area to the same height as Jacks idea. This reflects the Astra H's raised bit above it's fog lamps and will flow back into the bumper.
I started by drawing a template -
http://img.photobucket.com/albums/v13/danga/bumperfogs0005.jpg
One of the existing Punto headlight surrounds will sit in the middle (this is taken from my rear lights build) -
http://img.photobucket.com/albums/v13/danga/bumperfogs0007.jpg
I then transferred this to the bumper -
http://img.photobucket.com/albums/v13/danga/bumperfogs0002.jpg
http://img.photobucket.com/albums/v13/danga/bumperfogs0003.jpg
I then did some chopping, cutting and sanding and it came out like this -
http://img.photobucket.com/albums/v13/danga/bumperfogs0011.jpg
A bit more sanding and shaping as well as some sanding and shaping to add a curve to the lower section of the sides flowing to the front refined it further -
http://img.photobucket.com/albums/v13/danga/bumperfogs00017.jpg
http://img.photobucket.com/albums/v13/danga/bumperfogs00016.jpg
http://img.photobucket.com/albums/v13/danga/bumperfogs00015.jpg
http://img.photobucket.com/albums/v13/danga/bumperfogs00021.jpg
I'll take the honeycombe design from these panels into the backing that will sit behind the fog lights. The Punto light will fit into the middle of the centre bar and be angled to reflect the lights.
I also trimmed a small bit off the bottom section in the middle so the sides stand out more.
Saturday 22/02/2008
Was at a dinner dance last night with friends - all done up in my kilt and the wife had on a posh frock. Didnt get in till 3am and after eating what at the time was a lush chicken and mushroom pizza on the way home my ar$e feels like something climbed up it in the wee hours and died! God I feel like sh1te!
So today was a little slow...didnt get up till 12pm!
I decided to have a crack at the sections either side of the grill. Whatever I did would be temporary because I need to wait until my new OPC grill arrived. however I wanted to see what the bumper would look like with them in place...these are a wip...
http://img.photobucket.com/albums/v13/danga/bumperfogs00022.jpg
http://img.photobucket.com/albums/v13/danga/bumperfogs00020.jpg
http://img.photobucket.com/albums/v13/danga/bumperfogs00023.jpg
http://img.photobucket.com/albums/v13/danga/bumperfogs00024.jpg
They dont look too bad but I think theyre a little fat/wide. The good news is the new grill has a frame around it (which I need to fettle to fit slightly!) so all I have to do is add a simple line between the bumper and bonnet which I'm hoping will be straiht forward.
My head started to calm down a bit by mid afternoon (amazing what fresh coffee can do for the soul!) so as I'd taken my bumper as far as I could until the new grill arrived I had a garage clean up. Moved most of the left side of the garage into my neighbours for storage (theyre away until June!) because I wanted to start on the next section of my build...
My side skirts!
Saturday 22/02/2008 continued...
My side skirts are based on the Monaro's side skirts and are fairly straight forward. The hardest part was getting the profile right and ensuring the depth of the skirt was level with the bumper. The bottom of the skirt will be flush with the lip on the bottom of the arch which makes the skirts 10cm deep.
I started by making a profile template to reflect the undeside of the sills in card. Although these bits won't end up on the finished item I wanted to ensure I could offer up the foam parts to the sills without any problems and they would sit flat on underside of the sills.
the skirts themselves are 166cm long. Once the template was correct I cut the foam I needed and removed the excess using my bandsaw. The assembled bases were offered up to the car to ensure they fitted -
http://img.photobucket.com/albums/v13/danga/bumperfogs00026.jpg
http://img.photobucket.com/albums/v13/danga/bumperfogs00028.jpg
I need to add a little more foam to the back so they sit against the sill lip correctly but they fit very well.
I then drew the design onto the face of the skirt (this is very rough and a bit small )-
http://img.photobucket.com/albums/v13/danga/bumperfogs00030.jpg
http://img.photobucket.com/albums/v13/danga/bumperfogs00029.jpg
The design will be cut from foam and bonded to the front. The main lower section is curved and sticks out slightly towards the back. this will be carved into the face and additional foam added.
Here's a few ref pics -
http://img.photobucket.com/albums/v13/danga/mon4.jpg
http://img.photobucket.com/albums/v13/danga/mon2.jpg
http://img.photobucket.com/albums/v13/danga/mon5.jpg
http://img.photobucket.com/albums/v13/danga/mon1.jpg
and if ever I get arrested in Oz I wouldnt mind sitting in the back of this one -
http://img.photobucket.com/albums/v13/danga/mon3.jpg
nov4801
24-02-08, 07:37 AM
looking good mate. loving the front bumper btw
Matt2107
24-02-08, 10:03 AM
Excellent work Ade.... as always.
This surely must be worthy of a TV feature.
That Monaro GTS gave me a thought... how about painting the front bumper like this?
http://i13.photobucket.com/albums/a266/razorjack/Cars/ade2.jpg
nov4801
24-02-08, 12:09 PM
That Monaro GTS gave me a thought... how about painting the front bumper like this?
http://i13.photobucket.com/albums/a266/razorjack/Cars/ade2.jpg
i like that think it looks really smart
yeah - thats the plan - the fog light bars will also be anthracite.
MK1-GTE
24-02-08, 03:55 PM
mate you are a very talented fella ...
the work involved really is very impressive ...well done :)
bangerbrian
24-02-08, 04:10 PM
Wow, been read whole thread and it took me about 4-5 hours!, Keep it up :)
this is looking awsome mate cant wait to see it done
DW-Nova
24-02-08, 07:17 PM
Looking brilliant mate, been away for a couple of weeks and the progress is brilliant! everything is so different from the norm. one thing that dose suprise me however is the fact that loads of people arn't moaning about this project cause it's not got a GSI front bumper or cav slab wheels etc etc.. love the project myself though.
Looking brilliant mate, been away for a couple of weeks and the progress is brilliant! everything is so different from the norm. one thing that dose suprise me however is the fact that loads of people arn't moaning about this project cause it's not got a GSI front bumper or cav slab wheels etc etc.. love the project myself though.
Have to admit youre right there! Everyone is v supportive and the project itself is sort of a collaboration of everyones ideas (eg the fogs in the bumper!)
One thing though - I'm sticking cav slabs on it! lol Will be anthracite...
^ go for some VXR rims :D proper hardcore :thumb:
Sunday 24/02/2008.
Busy day today although I didnt actually do anything till about 11am apart from drink cups of Tea! I won a set of Punto fromt lights on ebay the other day for ?60 so I arranged to pick them up from the seller - he only lives about 40 mins away from me on the other side of Stirling so was a nice drive. Came of a Y plate but theyre minted and complete! He also had 3 SPL subs in enclosures (one with a curved perspex front with a built in 400w amp). One of the subs is duff but the other 2 were fine. Only wants ?30 for the lot! I didnt have the cash on me to buy them (also not what I'm after) so if anyone wants them let me know...
I decided to carry on with my side skirts in the afternoon. I'd taken some measurements and made the backs on Saturday but I hadnt actually seen them up against the car to check theyre the same depth as the front bumper. However pleased to say theyre okay. As you can see from the pics below the fronts are a little shy so I add 2cm at the front under where the vents are to go which also helps with the design - which I modified and stretched to go beyond the door edge (not shown below) -
http://img.photobucket.com/albums/v13/danga/skirt6.jpg
http://img.photobucket.com/albums/v13/danga/skirt5.jpg
Once I'd ensured the depth was okay I started to make the faces. These were cut from 15mm foam and then glued in place. I started by working out what foam I needed and laid it up to ensure it covered all points. No point cutting more than I needed -
http://img.photobucket.com/albums/v13/danga/skirt4.jpg
After I ensured the skirts were facing the right way (last thing I needed was 2 left or right handed ones!) I then drew on the new design and cut it from the face. The strips were then glued in place -
http://img.photobucket.com/albums/v13/danga/skirt3.jpg
This shot shows the extra 2cm I added to the front which really helps with the design -
http://img.photobucket.com/albums/v13/danga/skirt2.jpg
The next step was to start shaping them. Along the top edge theres a 2cm angle and the bottom of the front section where the vents are is also curved -
http://img.photobucket.com/albums/v13/danga/skirt1.jpg
That's all I managed to get done before the wife called me in for me tea.
Next job is to make the main bottom section. This is basically a traingular strip of foam (using the section I cut out from the face) but sanded to create the angle...
However this week I'm working lates so I probably wont get anything done now till next weekend.
:mad:
Mike you got any pics of the VXR rims? Also will they be the right offset? (hasnt this changed?).
unbelievable amout of work has gone in to this car hats off to you mate
Mike you got any pics of the VXR rims? Also will they be the right offset? (hasnt this changed?).
18's in a 5 x 110 @ ET37
http://www.pistonheads.com/pics/news/10366/Vauxhall_Astra_VXR-L.jpg
stunning work as normal ade!
Did I hear you were doing a 5 stud conversion?? lol
lol - nah - cant be ar$ed! Sticking to my "sensible" 15" cavvy slabs...
Welsh Dan
25-02-08, 08:12 AM
Seeing as you've put in a tremendous amount of effort ade, and that we can all see how good it is starting to look, and that I don't think cav slabs would suit it one bit, I think it would be a shame for the final product to be wearing wheels that don't suit it.
If you don't want to go to the effort of a 5stud conversion, then what about some softstars?
vaughanmc
25-02-08, 04:22 PM
Quality work Ade - Coming along nicely as well :)
DW-Nova
25-02-08, 07:53 PM
Looking very good as usual. As regards to the wheel's it's obviously your descision but i think that the choice of cavalier wheels will not suit the car, the rest of it is obviously really radical and different and i think that personally i would choose something different, would probably go for something 17 or 18", something that has never ever been done on a nova, i think that renault 4 stud wheels are the same stud pattern, if so the new shape meganes have some really cool looking wheels on, i had one, it was a dynamique with 17" alloys on that were really nice.http://www.direct-vehicle-leasing.net/images/car_images/renault%20megane%20scenic.jpg
DW-Nova
25-02-08, 07:54 PM
pitty about the rest of the car though hey!!
Blimey ade I must say what you've achieved so far is deeply impressive. To pitch in with your first go at welding and metal fabricating and produce the finish as good as you have managed is very creditable. I don't know what job you do but I have a feeling your talents are being wasted:D
I'm going to sound a right thicko but what do you do with the foam to produce the finished article - is it a former/mold to make something up out of glass fibre?
The reason I ask is cos I want to sort a rear spoiler to try out its possible effectiveness but I want something nice and light.
ade, im loving this project now.. i love the bumper and lights, looks alot better than nova items imo
im looking forward to the rear bumper and rear light progress, look like they could be tricky :thumb:
Wheels wise I have a set of cav slabs and will be sticking with these at the mo - budget wise the moneys tied up in other areas however soft stars or similar maybe purchased later on. I'm not wanting to go any bigger than 15's - 16's at a push simply because of the mods involved - dont want the hastle.
CP - as you said - the foam will be the former. the idea is to lay up a thin layer of glass fibre tissue and resin this over then skim with filler to get the desired look (the foam in slightly smaller to allow fot the thickness increases) - then the idea is to mirror glaze this and take a mold of fobreglass from it (gel coat, tissue and fibreglass) then mirror glaze the mold and make a cast (gle coat, tissue glass, fibreglass, woven roven, fibre glass and finally tissue glass.
However I'm worried about 2 things -
1. Potential undercuts - even if slightly shallow will make it impossible to release the cast from the mold.
2. Mirror glaze failure - had this happen to me before and the mold attached itself to the cast ruining all the hard work!
So I'm considering the following laying up the tissue and resin and skimming to get the right shape, then removing the foam and layering up the inside.
I'll need to wait and se how the final bumper looks once skimmed before I decide...
The rear bumper for your project though should be straight forward as there wont be that many undercuts.
Ade
dave.gsi
26-02-08, 08:09 PM
agreed on the wheels, once its all finished it'll look pretty much like a new car. to put it on 1980's wheels will just be criminal :eek:
i'd even advise staying away from speedlines and softstars as that'll give the game away too easily to anyone who's thinking 'what the hell is that car?'!
stick with factory vauxhall rims for the subtle look, but go for newer versions, something off the astra or corsa maybe? 16in definately :thumb:
novacabrio
26-02-08, 10:00 PM
Id agree on thee wheels comments, and like the ideal of the meganne wheels,
cant belive you dont want the hassle of fitting 17s etc, but your making your own bumper etc? Is that not more hassle?
nah - I've seen enough comments about handling issues with bigger wheels and I quite like the smaller sets. I'm tempted for 16' softstars of speedlines but tbh the wheels arent the priority at the mo...
DW-Nova
27-02-08, 08:16 PM
Not trying to start an argument about wheels here but 17" s wont ruin the handling, i've been in a couple of novas with 17's and was pleasantly suprised! i've driven a corsa with 19's on and this was going a bit far tbh but it wasnt as awful as i thought, anyway it's obviously down to you in the end, so long as your happy with the result! what i would do personally is the megane wheels, sprayed in anthracite with some opel centre caps, anyway good luck with the rest of the build, and cant wait to see the next update.
Nova18E
27-02-08, 11:01 PM
Very Original keep up the good wrk
Lee-170
27-02-08, 11:24 PM
new shape tigra wheels would suit it to a tee mate 5 spoke ones look awsome imo four stud fitment too :thumb:
http://www.astonvauxhall.co.uk/contribute-images/Tigra3_001.gif
EUROTURBO
27-02-08, 11:35 PM
ive gotta say this is the first time in about 5 years when i have been interested in a nova with a bodykit on but for some reason im intreagued......lol
Saturday 01/03/2008
Only had a few hours in the garage due to a party I was off to in the evening.
Managed to get my side skirts finished (foam wise). They look really good and are the spit of the Monaro ones! For some reason I didnt take any pics...
Took delivery of my Corsa B inner arch linings for the from arches in the morning -
http://img.photobucket.com/albums/v13/danga/bay0006.jpg
I'm really impressed at how snug they are -
http://img.photobucket.com/albums/v13/danga/bay0007.jpg
http://img.photobucket.com/albums/v13/danga/bay0008.jpg
They need modding just slightly (plastic panels around the turrets and some mounting areas) and I need to make some clips to secure them.
Anyway - I decided to weld some areas in my engine bay - felt it necessary to reinforce the light surrounds (may as well do it "properly" now I have a welder!). Also thought (after seeing several rebuilds to the same) to reinforce the strut tops and sides of the bay with additional beads of weld.
Started off by removing the paint and seam sealer -
http://img.photobucket.com/albums/v13/danga/bay0004.jpg
http://img.photobucket.com/albums/v13/danga/bay0005.jpg
and in doing so came across this nice hole in me inner wing (feck knows how I missed it before!) -
http://img.photobucket.com/albums/v13/danga/bay0001.jpg
Also directly below it where the engine loom harness goes into the body notices the join was totally fecked!
http://img.photobucket.com/albums/v13/danga/bay0013.jpg
Thankfully this is more cosmetic as when the arches were replaced a couple of years ago the guys that did it welded up the hole directly beneath - however the big gap is a perfect water trap so may as well stick a sheet of metal over it.
Also came across this wee bugger tucked in the corner of the skuttle panel (passenger side) -
http://img.photobucket.com/albums/v13/danga/bay0012.jpg
With all this cleaned up and krust'ed I called it a day...and went and got blootered!
Sunday 02/03/2008 (afternoon).
Impressed myself by not having a sore head. The party (wifes works do) involved lots of scantily clad women doing the can-can - GOD they cannae half stick their legs over their heads!
Anyway - Today I are mostly be welding panels in place of rusty bits.
Started with the "cosmetic" gap behind my passenger side turret -
Before -
http://img.photobucket.com/albums/v13/danga/bay0013.jpg
After -
http://img.photobucket.com/albums/v13/danga/bay0016.jpg
and with a healthy dose of etch primer -
http://img.photobucket.com/albums/v13/danga/bay00017.jpg
inner arch before (trimmed rust away) -
http://img.photobucket.com/albums/v13/danga/bay0017.jpg
After (with primer) -
http://img.photobucket.com/albums/v13/danga/bay00022.jpg
Welds are a little messy but its a really tight area however I'm pretty confident I got full penetration.
Little skuttle panel area before -
http://img.photobucket.com/albums/v13/danga/bay0012.jpg
After -
http://img.photobucket.com/albums/v13/danga/bay00023.jpg
This one was an absolute biatch to get to - it's messy but tbh I dont really care - theres no gaps (based on me shining a torch on it and looking underneath) and it'll get a big wad of sealer over it.
In fact they all will.
Next step is to do some beads around the turrets, sides and the light housings. I also used me new fangles spot weld drill bit to pre drill some holes in the slam panel section I welded the other week so I can puddle weld it to the undrside making it uber strong!
Looks like swiss cheese at the moment...
http://img.photobucket.com/albums/v13/danga/bay0009.jpg
Will weld it up tomorrow...
:cool:
just read from start to finish that front end is amazing! really fond of that! good to see someone breaking the mould of gsi kitting novas up! can't wait to see it done
maccas
vaughanmc
02-03-08, 10:55 PM
Good progress mate :)
The Project is still going strong i see.
Get on ade
mikey14sr
03-03-08, 11:50 AM
lol, had my welder out at novalicious's yesterday doing an inner wing, managed to get smoke out of the back of the welder itself! don't know if he's got the pics up yet, but the vertical bit behind the turret looked like yours, but what was hidden was a lot nastier.
liking the progress ade. with those messy welds just do like i did....plenty of selaer and underseal :thumb: no one will ever know
liking the progress ade. with those messy welds just do like i did....plenty of selaer and underseal :thumb: no one will ever know
lol thats the plan until I get good at welding!
Thankfully all the rusty bits will be pretty much hidden away from view!
:thumb:
Thursday 06/03/2008
Day off work so more garage antics. Beforehand though was watching Discovery Channel (American Hotrod) and at the end it said Boyd Coddington had died! Pretty shocking. The guys was a god of the hot rod world in America...
Anyway - decided today to "patch up" my engine bay. There were a couple of areas that needed some welding and I thought I'd also weld round my strut tops nowt like a little bit more metal. I also decided to weld up the backs of my light housings so theyre 100% solid!
As you know my welding is still developing so the welds are a tad rough looking however I'm pleased to say that after all the shutz from the inner arch caught fire and melted away I can confirm I got full penetration!
lol
The bloody stuff stinks too!
Heres some pics -
http://img.photobucket.com/albums/v13/danga/engine0001.jpg
http://img.photobucket.com/albums/v13/danga/engine0005.jpg
This one shows the plate I welded in (same place both sides) - the metal beneath is rust free but the join is really thin and gone in places so I decided to strengthen it.
http://img.photobucket.com/albums/v13/danga/engine0008.jpg
I then ground the tops off the welds to neaten them up and etch primed the lot -
http://img.photobucket.com/albums/v13/danga/engine0011.jpg
http://img.photobucket.com/albums/v13/danga/engine0012.jpg
All the new welds will the fully seam sealed so they wont be obvious once theyre painted up.
I also did the slam panel - drilled plug holes all over it (see prev posts) and plug welded them up. This just needs a skim of filler to remove any dimpled areas.
http://img.photobucket.com/albums/v13/danga/engine0013.jpg
Just spent that last 3 hours removing another virus from my computer so whilst that was going on I wrote a massive list of things to do.
Although I'm not too sure where to start next...still waiting on parts for the front (new grill etc) and I need a bigger bottle of gas before I can do any more welding!
:wtf:
Ade, your welding is coming along leaps and bounds cheif :D
vaughanmc
07-03-08, 07:39 AM
Looking good sir - Keep it up :)
nov4801
08-03-08, 03:09 AM
looking good mate keep it up
DW-Nova
08-03-08, 11:30 PM
Looking good as ususal mate, looking forward to the next update, your welding skills are starting to get better too, well done and good luck with the rest of it.
weldings gettin better mate, comign along now..
keep it up..
Monday 10/03/2008
Bit of an ar$e weekend - my Ibiza broke down on the way home on Friday - engine just died on an A road - oil light came on and engine cut out - which made power steering cut out - I was doing about 60 at the time - pretty unnerving but had enough speed to get in on the verge although was on a corner. Phoned Greenflag who came out and reckoned it was either crank sensor or coil pack (?) or ECU so towed me to local garage - dumped car and I went home. Had to suffer getting a bus to work over the weekend. :mad: So booked today off to get car sorted. Unfortunately the garage couldnt get the car fixed today (waiting on parts) which means another annoying bus trip tomorrow :mad:
Decided to finish off my slam panel today - I'd plug welded the new skin to the underneath one the other week bit although its solid it doesnt look very nice - it's uneaven in places and no amount of dolly work was going to sort it - plus I wanted something that would channel the air coming from under the bonnet. So I made a fibreglass show cover.
The prinicple is very easy and would also allow me to practice my fibreglassing ready for when I start my bumper/skirts. I started by laying up plastecine modeling clay all over the slam panel to even it out. This was then shaped and skimmed to get it nice and flat. I used a spirit level at specific points to ensure it was even.
The slam panel looked like this beforehand -
http://img.photobucket.com/albums/v13/danga/engine0013.jpg
I made a card template to ensure both sides were even (they were pretty much spot on anyway but I wanted to be sure) - Heres the result after the plastecine cover was built -
http://img.photobucket.com/albums/v13/danga/paneltop0002.jpg
http://img.photobucket.com/albums/v13/danga/paneltop0004.jpg
http://img.photobucket.com/albums/v13/danga/paneltop0005.jpg
The masking tape covers bare metal areas. As you can see it is much more even and will protect the metal underneath.
Using the template I cut out some glass fibre matting allowing for folds over the edges. I mixed 400ml of resin and applied this directly on to the plastecine (it wont stick obviously as its nice and smooth) and then put the fibreglass on top. I then worked more resin into the fibreglass using a 2" brush in a stippling motion (basically you dab at the fibreglass with the end of the brush to get the resin to penetrate it and knock the air bubbles out). This was applied all over leaving additional material to trim where it wasnt needed -
http://img.photobucket.com/albums/v13/danga/paneltop0006.jpg
http://img.photobucket.com/albums/v13/danga/paneltop0007.jpg
I then applied a tissue layer (basically fibreglass matting but tissue thin) - again stipping with additional resin (only used about 250ml this thime though) - the tissue is like cotton wool and it clings and catched on everything so I needed to work carefully but fast.
It's currently curing in my garage but its pretty cool out tonight so have the heaters on to try and keep temperature even...
I'll post pics once I've trimmed the excess material off but I'm really happy with it and it's so much better than the plain metal panel. In addition it'll give my grill something to bolt striaght on to.
To fit I'll simply paint up the slam panel and then apply a nice even bead of body adhesive (eg tiger seal) - then simply pop the panel on and seal the edges.
Job done
:thumb:
cheers - just checked it and its cured purfectly - got a nice finish - just needs a trim and a very light sand back - I might not even do that - just leave it mottled...
Wednesday 12/03/2008
The missus went nuts at me the other day coz the smell of fibreglass resin got into the house off me trainers/overalls and stunk the place out! Doesnt help having the garage attached to the house either!
Anyway - started off by trimming off the excess matting and then removed all the plastecine (a pain in the bum) but it came out really well (its not attached yet) -
Will probably paint it black the same as the rest of the engine bay...
http://img.photobucket.com/albums/v13/danga/bumper0001.jpg
http://img.photobucket.com/albums/v13/danga/bumper0002.jpg
http://img.photobucket.com/albums/v13/danga/bumper0007.jpg
http://img.photobucket.com/albums/v13/danga/bumper0008.jpg
I then decided to lay up a couple of layers of fibreglass on my bumper. Even though I'm still waiting for my new grill I can still make a start on the rest of the bumper. This took pretty much all day. I started by cutting up a fair amount of fibreglass. The glass I was using is pretty thick (4 layers) so because this layer is simply to get the basic shape I needed to split it so it would bend and shape easier. All you do if find and edge and peel it apart. Doubles the amount you have
Heres the results after just one layer -
http://img.photobucket.com/albums/v13/danga/bumper0003.jpg
http://img.photobucket.com/albums/v13/danga/bumper0004.jpg
http://img.photobucket.com/albums/v13/danga/bumper0006.jpg
http://img.photobucket.com/albums/v13/danga/bumper0005.jpg
I removed the bar in the fog light area simply because it will be part of a seperate structure.
I then added a second layer and by this time the whole garage stank of resin. So with it being 6pm and the missus being home at 7pm and me having access to next doors garage I moved the whole bumper and work benches there instead. Opened oll doors and wildows and stuck all my clothes in the washing machine!
It worked - didnt get into trouble! (except now when I close my eyes all I can see are my hands in latex gloves covered in strands of fibreglass! - think the fumes have gone to my head!)
DW-Nova
12-03-08, 10:00 PM
Some good progress there mate, the cover for the slam panel is a neat touch and the bumper is now really looking to be coming along, top quality work as usual, look forward to seeing the next update.
Really liking the lateral thinking thats going into this Ade :thumb:
Matt2107
13-03-08, 08:51 AM
Excellent Ade.
If your missus nags too much do what I do and offer her a disposable face mask. :D
Saturday 15/03/2008
Took delivery of some parts today - my new OPC Grill (the Astra H one with the honeycombed vents and chromed strip) and 2 lower honeycombed panels as well as some bumper edge adjusters and suspension bolts. The grill is stunning and because it has the full surround will fit perfectly on the front of my Nova (once modified!)
Spent most of today sanding back the 1st layer of fibreglass on the bumper to get a flat surface to work from. The foam base, although flat, did have some unever spots in it. Once sanded back (and after changinf my clothes necause fibreglass dust gets everywhere and it pretty nasty stuff in the scratchy itchy department!) I put the bumper in place to get an idea of the depth.
http://img.photobucket.com/albums/v13/danga/bumplam20002.jpg
It definately needed another layer (which I planned to add anyway).
here's one with the new honeycombed grill section -
http://img.photobucket.com/albums/v13/danga/bumplam20001.jpg
This will also form the back for the fog lamps.
The second layer was made out of 2 long pieces of fibreglass which will add strength across the face of the bumper. The next task is to sand this back lightly (to remove the evil burs and skelfs that are as sharp as needles) and skim the entire front with body filler. This will bring up the thickness to the correct levels and allow finer detail to be applied.
Here's a couple of pics with the bumper in place. It's bolted on at the corners of the lights and held in place with the big clamps at the side -
http://img.photobucket.com/albums/v13/danga/bumplam20005.jpg
http://img.photobucket.com/albums/v13/danga/bumplam20006.jpg
http://img.photobucket.com/albums/v13/danga/bumplam20004.jpg
http://img.photobucket.com/albums/v13/danga/bumplam20003.jpg
The old grill isnt sitting right on the pics but the new one will fill the whole grill section fully!
From this (once cured) I'll skim
vaughanmc
16-03-08, 10:24 PM
Looks amazing mate - Keep it up :)
looks brillaitn ade, love the 2 head on pics :thumb:
you need my ?100 tho to finish it off :thumb: :D
WOW
nothing else to be said
Ade all i can say is wow! i have passed where you live a few times on the way to kennacraig for the ferry, always thougth of just having a drive in by to see if you were working on this lol.
Keep it up mate
DW-Nova
17-03-08, 10:30 PM
brilliant mate, the bumper is going to look amazing once it's done, it's all keeing together very nicley now, is everything going to be smoothed into the body? as regards to the paint job, will this be DIY or you getting it done?
not planning on smoothing the kit into the body - no point because the 1st pot hole and it'll crack anyway! Will have very small join lines between bumper and wings.
As for respray - gonna get it done properly this time - I enjoyed doing mine but I want it done properly this time.
Saturday 22/03/2008
God I can't believe its almost April!
Anyway - cracked on with the bumper - todays task was to get the filler on it so I could get some finer lines into the design. I've decided to take a mold from this and take a proper cast - simply because the amount of filler that will be needed to shape it properly means it'll be pretty weighty. I also want it done properly...and if anything happened I've always got the mold to make another bumper from!
Started by sanding back the last layer of fibreglass to remove any sharp burrs. I then put on a skim of filler -
http://img.photobucket.com/albums/v13/danga/bumperfiller10001.jpg
and sanded this back to fill any major differences -
http://img.photobucket.com/albums/v13/danga/bumperfiller10003.jpg
http://img.photobucket.com/albums/v13/danga/bumperfiller10006.jpg
It was then a case of fill and sand, fill and sand until I had it pretty close to the final size -
http://img.photobucket.com/albums/v13/danga/bumperfiller10013.jpg
http://img.photobucket.com/albums/v13/danga/bumperfiller10011.jpg
http://img.photobucket.com/albums/v13/danga/bumperfiller10015.jpg
http://img.photobucket.com/albums/v13/danga/bumperfiller10017.jpg
As you can see I've started to blend it into the wings - the cracks are deliberate - they give me an indication on where I can work up to.
the next task is one moe layer of filler, sand back then measure it up to get the final details for more finer detailing. I then need to check that there are no serious undercuts, sort them, prime it and take a mold from it.
nov4801
23-03-08, 07:35 AM
absolutly stunning mate, the attention to detail is amazing.
DW-Nova
23-03-08, 04:20 PM
Looks brilliant mate, you must have put so much time into doing that, do you have a orbital sander yeh? if not i i really reccomend getting one as the amount of time it saves is unreal. The car is going to look amazing once done, the skirts are going to be essential to tie it all together, good luck with making the mould for the bumper.
I dont have an orbital sander (not the standard round ones anyway) - just a standard black and decker flat rectangle sander (its also v noise for some reason!) - also have a sanding mouse and a dremmel...although do a fair bit bu hand.
Sunday 23/03/2008
Spent the morning taking pics of the wife riding her horse over jumps (been neglecting the wife of late what with the car and all that!).
However the afternoon I spent in the garage - basically just adding more filler, getting the lines right and trying to work out the gaps round the lights and wings.
It's looking pretty good but theres still lots to do.
I've decided to use Vynamould to make the mould rather than risk damaging the bumper if the mirror polish doesnt take proplerly. Vynamould is basically like silicone rubber but you melt it and then pour it on the item to be cast. Its pretty viscous and can be spread thinly. Once the whole bumper is covered I'll lay over some fibreglass for strength and then I can cast straight on to this. Will be much easier/safer. I'll probably end up making a 2 part mould due to the wheel arch ends.
jimbob-mcgrew
24-03-08, 02:37 AM
omg ade, what have you done to that poor nova.
omg ade, what have you done to that poor nova.
created a machine, if you dont think thta looks good then you must be blind!
omg ade, what have you done to that poor nova.
lol - I was wondering when someone would challenge the look of the car! This I think is the 1st "slagging" lol
Granted it's not to everyones taste however the base car was shagged so rather than restore it to its former "glory" I decided to make something slightly different - original but more up to date...
I invite you to come back in 6 months time (or so) and take another look...it is still very much a work in progress.
As for the poor Nova - well some may say yes, it's a bit off the wall and detracts from the original car, to be honest I always wanted to do something a little different and this (being my 1st car) was the ideal choice. It was off the road anyway collecting dust.
Can I ask that to help keep me motivated you perhaps point out what you think works well or suggest anything that would improve it (apart from perhaps scrapping it all together) - I intive you to read the whole thread from the start to - that way you will see the design take shape and hopefully understand the concept a little better rather than make one simple comment about the original car - you will also see the suggestions from fellow Nova owners and how they get incoprerated...
Oh and please note to anyone tempted to copy images and send them to those modding car hating sites - the filler is there for a reason - its part of the "master" that will form part of the mold to make proper fibreglass parts...
I thank you...
:thumb:
I'm really impressed with how the lights/bonnet/wings/grill/bumper are looking ! The Swage lines, bonnet lines and the lines made by the box aches really tie in with the front end (think theres something to be said about vauxhall design there)
However, from the windows up it looks like a completely different car. I don't really see how you're going to get around this, or do you have some trick up your sleve ?
I guess a top-notch paint job will help tie it all together.
I think I agree with nick, if you look at newer cars the windows also seem flush with the body work, where as the nova's are resessed in slightly...
DW-Nova
25-03-08, 07:47 PM
I kind of agree with what is being said above about the back half of the car, however i reckon that once the skirts are all in place and the car is all nicley painted it will look brilliant, i reckon that it'd break it up nicley if you black out the windows with the bright yellow paintwork.
No-ones talking about the back half of the car... we're talking about the top-half.
I agree a paintjob in a modern metallic colour will help, but i still think the skip-like profile of the roof/pillars just isn't going to look 100% right
omg ade, what have you done to that poor nova.
As ade said it may not be to everyones taste but surely nobody can overlook all the work thats gone into this!
Amazing project ade, cant wait to see it finished :thumb:
wisewood
26-03-08, 04:42 PM
Its coming along nicely mate. I like it. Is it going to be a front end only thing or will you be modding the rear too - PM me in response please mate, i dont fancy fishing through the thread to find a reply next time i get chance to come on here lol
^ Yup, iirc there was work done on the boot to fit a funky badge and boot release ;)
Needs speedlines and a GSi kit to look proper bo though
Re the skip comments - I do agree that from the middle up its gonna look like a standard nova however I think the paint job and other parts (skirts, back end etc) will detract sufficiently from this.
I had considered rolling the roof gutters - basically get a length of steel rod and tap the edge back then weld the edge - saw it done on American Chopper on an old hot rod and it looked really good. not sure though...
TBH I'm not that bothered - for me it's more about whether I can complete each task and get to the end...
I'm hoping the experience I gain from this project will help me when I move on to buying a "proper" kit car - I'm after a Caterham 7 kit...
:cool::thumb::D
I'm after a Caterham 7 kit...
*cough* Ginetta G4 :cool:
Wednesday 26th March 2007
Fecking cold today - snowed in the morning and rained in the afternoon however I cracked on as usual and drank enough coffee to p1ss brown liquid!!!
I'd intended doing more work on the bumper today but decided before I can really do any more on this I need to install the new grill to ensure that it fits and matched the bottom par of the bumper.
Took me all day!
I'd purchased a brand new OPC Astra H grill (honeycombed version) and chromed Opel blitz panel. The task is to reduce this to fit snuggly between my Punto lights...
After bolting on my wings properly, reseating the bumper, adjusting the underside of the bonnet (the blitz badge mounting is HUGE) and several measurements, checking and rechecking distances and marking up the panels I got me dremmel circular saw attachment out and "customised" the grill sections.
Thankfully everything went smoothly (apart from a nice deep cut across the side of me left index finger) and the grill pretty much slotted in perfectly!
Theres a couple of adjustments thats needed on the bumper - the underside of the grill where it sits in the bumper need tidying up and the front needs raising slightly but thats a simple filler job which I expected - hence doing this job today...
I had to remove a fair amount of the grill back mounting and ends so I still need to fashion some mounting clips but it tucks in nicely under the bonnet and the chrome lines butt up to the edge of the lights. This leaves enough room for an edging peice (the card bits in the pics below) to run up from the bumper to the underside of the chrome.
Anyway - heres some pics...
http://img.photobucket.com/albums/v13/danga/bumpergrille0008.jpg
http://img.photobucket.com/albums/v13/danga/bumpergrille0004.jpg
http://img.photobucket.com/albums/v13/danga/bumpergrille0007.jpg
http://img.photobucket.com/albums/v13/danga/bumpergrille0003.jpg
Next task is to skim the gaps under the grill to raise the bumper middle, then clean up the bumper proper...
Working this weekend though so may tinker over the next few days...
nov4801
26-03-08, 10:24 PM
love it ade, that front end is stunning.
Neil 08
26-03-08, 10:33 PM
there must be a huge amount of hours spent on this car already and its only the front end thats being done,
absolutely fantadtic work mate
Nice one Ade, glad to see it's coming on well and your adapting to the welding.
vaughanmc
27-03-08, 07:38 AM
Looks f*ckin mean mate :)
Love it !!
shy witness
27-03-08, 07:21 PM
great work again mate.
for some reason 1 or 2 of them pictures show a resemblance to a mazda 6(or some other model)
serious ammount of work going into this...keep it up mate
DW-Nova
27-03-08, 09:04 PM
wow, looking amazing mate, the front end is looking really good already. i really like the sound of what you said about doing to the roof gutters, they really do age the car alot, when you see a de-seamed mini it really dose transform the car, i think it'd do the same with this.
Problem with deseaming a nova is that the windows look odd afterwards
great work again mate.
for some reason 1 or 2 of them pictures show a resemblance to a mazda 6(or some other model)
serious ammount of work going into this...keep it up mate
Mazda 6 - tbh I quite like the Mazdas - like the rear clusters on them - v sleek looking. The grill sections are sort of v shaped as below -
http://www.digimods.co.uk/images/Virtualcarimages/cars/mazda6.jpg
Matt2107
28-03-08, 08:28 AM
Mazda 6 MPS is where it's at.
I work above Mazda, Mitsi and Volvo and exlcuding the EVOs the 6 MPS is by far the best looking model on our forecourt.... even better than the RX8s
DW-Nova
05-04-08, 09:11 PM
Hello there mate, you done any work on the Nova recentley? look forward to seeing it.
Sunday 13/04/2008
Been busy sanding and filling over the last few days and have pretty much completed the master for the front bumper.
It's been primed and from this I can see where the finer details need touching up (more to do with getting the lines right etc). I've even made the ends that go under the wings.
here's some pics...
http://img.photobucket.com/albums/v13/danga/bumperprime0001.jpg
http://img.photobucket.com/albums/v13/danga/bumperprime0002.jpg
http://img.photobucket.com/albums/v13/danga/bumperprime0003.jpg
http://img.photobucket.com/albums/v13/danga/bumperprime0004.jpg
And with it on the car - its only held in place by 2 screws behind the grill - no bumper brackets or owt (apart from the 2 little wooden sticks in each corner!) -
http://img.photobucket.com/albums/v13/danga/bumperprime0007.jpg
http://img.photobucket.com/albums/v13/danga/bumperprime0008.jpg
http://img.photobucket.com/albums/v13/danga/bumperprime0009.jpg
http://img.photobucket.com/albums/v13/danga/bumperprime0017.jpg
http://img.photobucket.com/albums/v13/danga/bumperprime0018.jpg
http://img.photobucket.com/albums/v13/danga/bumperprime0016.jpg
Welsh Dan
13-04-08, 11:27 PM
It looks great ade :thumb:.
chimp007_uk
13-04-08, 11:27 PM
schweeeeeet... your craftsmanship is unreal :)
Sunday 13/04/2008 continued...
Now the front bumper master is pretty much complete the last coupld of days I've been working on my side skirts.
I carved these from foam a while ago to get the basic shape -
http://img.photobucket.com/albums/v13/danga/bumperprime0020.jpg
Theyre similar to the monaro ones (see prev posts).
Started by hot glueing the foam core to a length of wood to keep it straight. I then layed up a layer of fibreglass -
http://img.photobucket.com/albums/v13/danga/bumperprime0023.jpg
http://img.photobucket.com/albums/v13/danga/bumperprime0024.jpg
Since then (last Tuesday) I've covered both in filler and have been sanding like a nutter and both skirts are pretty much complete in terms of the basic outline shape. I'll post pics when I get chance...
Next step is to check the angles and add finer details hich include the vents at the front...
novacabrio
13-04-08, 11:30 PM
MK3 Nova?
NovaLad
13-04-08, 11:32 PM
MK3 Nova?
lol
Your work is awesome!
vaughanmc
13-04-08, 11:34 PM
Awsome work mate
Nice meeting u today as well :)
Mike B GTE
14-04-08, 09:58 AM
bloody hell mate - how well does that bumper fit??? excellent work! :thumb: :thumb:
DW-Nova
14-04-08, 09:58 PM
Brilliant as per usual! That bumper looks amazing!!! it really dose look like it's came out of a factory and not been made by yourself in a garage, Factory fit or what hey, should be proud of yourself. Amazing Work.
Cheers guys!
I'm well chuffed with it - theres still work to be done on it to get it 100% but it's come together really well...
Mike - the fit's okay - still some work to be done getting all the gaps right.
Tuesday 15/04/2008
As promised, heres some pics of one of the side skirts.
I've spent the last week working on both sides and this one is almost finished. Some tinkering to do but it's been separated from its wooden board and apart from the vent detailing it's pretty much ready for priming and final finishing ready for the mould.
Based on feedback and if the mold comes out okay I may flog these (and the rear bumper if it comes out okay)....
basic skirt
http://img.photobucket.com/albums/v13/danga/skirtsfil0010.jpg
inside (foam core - some of it removed)
http://img.photobucket.com/albums/v13/danga/skirtsfil0011.jpg
test mounted to the car
http://img.photobucket.com/albums/v13/danga/skirtsfil0012.jpg
http://img.photobucket.com/albums/v13/danga/skirtsfil0021.jpg
http://img.photobucket.com/albums/v13/danga/skirtsfil0019.jpg
http://img.photobucket.com/albums/v13/danga/skirtsfil0022.jpg
aligned with front bumper height
http://img.photobucket.com/albums/v13/danga/skirtsfil0015.jpg
http://img.photobucket.com/albums/v13/danga/skirtsfil0006.jpg
side on
http://img.photobucket.com/albums/v13/danga/skirtsfil0014.jpg
close up (less detailing)
http://img.photobucket.com/albums/v13/danga/skirtsfil0005.jpg
The penned in detailing will be routed out to form 3 indentations - the rear parts of these will rise to form a curve similar to the monaro ones and will be tapered to follow the slight curve of the wing/door gap...
looking at the pics I may actually make the top line a little deeper...perhaps add another 15mm along the top length...
novacabrio
15-04-08, 10:49 PM
quality work, how hard will the mould be to make?
shouldnt be that hard. basically you prime them and then smooth them to get really smooth finish. You then cover in a product called mirror glaze and buff until really shiney - its a release agent/wax.
you then basically cover in gel coat (which is like a final resin top coat), then tissue matt then fibreglass (2 layers for rigidity), Once cured, remove master from mold (praying the release wax has worked!).
You then mirrie glaze the inside of the mold and reverse the process - gel coat, tissue, prob 3 layers fibreglass and a final layer of tissue.
The ends need finishing in the pics above - the skirts need measured for exact length.
I've worked out a mounting system for them as well rather than rivets - will be seamless and hopefully easy to apply...
dave.gsi
16-04-08, 07:07 PM
^^ i was just going to ask you about how its going to be attached......
from the mold you'll get your new bumper but it'll just be a fibreglass shell with no mounting points?
are you fitting the standard nova mounting bar behind it or is it going to be screwed on with hidden screws somehow? or bonded on?!
when i did mine i chopped up an old sr bumper and just kept the top 6 inches (which holds all the standard mounting gear) and made the bumper mold over the top of it so i could bond the new fibreglass shell on to it ---->
http://i192.photobucket.com/albums/z252/daveonearm/Picture196.jpg
dave.gsi
16-04-08, 07:16 PM
and almost forgot, people were talking about the top half looking like a skip..........
i kind of agree, the front end will look amazing, like a new car, but from the side profile as soon as you see the nova archs/doors/roof etc it'll be a dead giveaway.
i'd be half tempted to do something with the archs..........maybe even some round arch trims over the top of the normal archs? it'd be a crime on a normal nova but on yours it may just work if you get the right wheels to suit.
also, i found an nice picture you may be interested in. look at the C pillar on this..........
http://www.netikka.net/modcars/projektit/Corsa/Kuvat/isot/Kuva20059.jpg
i think that looks amazing and it definately detracts from the 'boxy nova/skip look'! you could even do something similar with the A pillars to make it more rounded?
i know its all a lot of work but i hope ive given you some stuff to ponder over lol
what in holy fcuking hell is that:eek:
dave.gsi
16-04-08, 07:24 PM
its pretty mental isn't it?!
it went downhill though....check it out here.......
http://www.netikka.net/modcars/projektit/projektit.html
(opel corsa a)
DW-Nova
16-04-08, 08:20 PM
Loving the looks of that corsa a, the arches and c post mod really make it look like a different car, how about a set of combat arches on your nova ade? agree with you dave.gsi, the corsa looked mint in the mat black paint but the new paintjob really spoiled it.
ahhh i remember it now dave
looks great ade, love the front end, very very professional :thumb:
you can crack on with my model now :D:D :thumb:
dot worry Dave I'll be starting the models this weekend if I get 5 mins...need to finish the other skirt 1st though.
As for arches - nope they'll be staying standard although the above nova's fabrication is pretty impressive. Theres a nice one of it in orange somewhere - the rear lights/bumper are pretty cool but the latest front end is a bit too much for me. Like it in satin black though...
how about using bmw mini lights at the back to match the modern theme at the front
http://img520.imageshack.us/img520/3669/image451bx5.th.jpg (http://img520.imageshack.us/my.php?image=image451bx5.jpg) (i got this pic off my old pc its someones off here)
what ya doing with the rear mate? and what wheels you going for? unreal the detail your going into mate! keep it up and can't wait tosee it finished!
how about using bmw mini lights at the back to match the modern theme at the front
http://img520.imageshack.us/img520/3669/image451bx5.th.jpg (http://img520.imageshack.us/my.php?image=image451bx5.jpg) (i got this pic off my old pc its someones off here)
The new Mini is a bubbly/rounded design. The nova, and all the work so far is concentrating around an angular but modern design... So i think those BMW mini lights would look absolutly terrible, as they do on that !
Matt2107
20-04-08, 08:37 PM
Ade's got a custom job up his sleeve for the rears.
Go back a few million pages.
lol!
Year the rear will have a standard mk2 spoiler, flushed boot with a modified VW boot opener (the badge that lifts up) - replaced with an Opel badge - detailing either side this will reflect the chrome bar across the front. Am about to start on the rear bumper but 1st need to do a bit of work on a couple of models... See page 7 of thread for basic design of rear...
As for lights will be making my own similar to these but using those from a landrover!
http://www.netikka.net/modcars/projektit/Corsa/Kuvat/isot/Kuva20004.jpg
They will be recessed though
Matt2107
01-05-08, 01:16 PM
Update por favor?
not had chance for a few days - been working lates and the wife's been dragging me all over the fecking central belt looking at houses in my spare time! (shes relocating jobs).
Also been working on Dave's and Vaughan's models in time for PV.
And my last excuse is the weather on my days off has been totally sh1te!
I WILL however get the rear bumper started and hopefully shaped this weekend as I'm off work till next Tuesday!
vaughanmc
02-05-08, 08:29 AM
You'l need to send me some pics of what you've done to my model Nova - I can't wait to see where your at :)
Matt2107
02-05-08, 08:53 AM
I WILL however get the rear bumper started and hopefully shaped this weekend as I'm off work till next Tuesday!
Excellent... I'll have plenty to read and look at when I get back from my holiday. :D
Sunday 04/05/2008
Today I are mostly be building a rear bumper...
The rear bumper will be made in a similar way to the front - a foam core overlayed with fibreglass the filler to get the exact shape. A mold will then be taken and a fibreglass bumper assembled.
As I'm smoothing my boot, the bumper will have a number plate recess and I wanted to do something to highlight the exhaust.
I started with the basic shape which is effectively one single peice of foam across the back . I had to stick a few bits on the end because the foam wasnt long enough (typical) and put a few strips behind it to build it out to get the right depth. Its about 20mm shallower than the standard bumper but is much deeper (closer to the floor).
After I'd build the basic "box" (effectively a panel across the back and sides), I cut out the plate recess and exhaust area -
http://img.photobucket.com/albums/v13/danga/rear0005.jpg
http://img.photobucket.com/albums/v13/danga/rear0006.jpg
I then resat these sections to take into account the final curve of the bumper -
http://img.photobucket.com/albums/v13/danga/rear0007.jpg
http://img.photobucket.com/albums/v13/danga/rear0008.jpg
http://img.photobucket.com/albums/v13/danga/rear0009.jpg
http://img.photobucket.com/albums/v13/danga/rear0010.jpg
I then needed to see what it looked like with my smoothed boot. So I took my standard one off and fitted the smoothed one. For reference I've decided to ditch this actual boot and will be making a proper welded one (this ones just too heavy). Did a bit of sanding and hey presto - basic bumper shape -
http://img.photobucket.com/albums/v13/danga/rear0011.jpg
http://img.photobucket.com/albums/v13/danga/rear0013.jpg
http://img.photobucket.com/albums/v13/danga/rear0014.jpg
http://img.photobucket.com/albums/v13/danga/rear0016.jpg
http://img.photobucket.com/albums/v13/danga/rear0017.jpg
http://img.photobucket.com/albums/v13/danga/rear0021.jpg
http://img.photobucket.com/albums/v13/danga/rear0020.jpg
http://img.photobucket.com/albums/v13/danga/rear0002.jpg
http://img.photobucket.com/albums/v13/danga/rear0019.jpg
Atill need to tidy up angles and havent really started the sides but it's pretty much there...
nice work...
recon another tail pipe on the otherside would look good when it's done :)
wilson_sri
04-05-08, 11:52 PM
Looking good man! Always good to see something differant getting done :)
You still interested in these audi door handles?
novacabrio
05-05-08, 09:06 AM
I can't belive the hours this must be taking, you have the patients of a saint!! I think i'd of got board a hell of a long time ago!
mikey14sr
05-05-08, 10:29 AM
Cut the whole skin off the bottom of the bootlid and weld/crimp a fresh flat sheet on, thats the best way to do it. Or cut it off and use one of them fibreglass flushing panels.
vaughanmc
05-05-08, 10:33 AM
Nice back bumper as well :)
I'd only make the number-plate recess a bit deeper ?
mikey - I discovered the boot lid is actually slightly warped somehow?!? so doesnt actually close properly (hence tape at the corners)
Vaughan - plate recess is deeper than the pics show...
vaughanmc
05-05-08, 11:11 PM
Ah the pics make it look shallow
Should be nice all in all once its done like :)
decent weather the last few days (for a change) so heres a few pics with the master parts of the kit in place. The rear bumper has now been fibreglassed and is waiting for finer detailing.
Once thats done the kit is ready for molds to be taken and then I can crack out the actual parts to be used on the car...
http://img.photobucket.com/albums/v13/danga/rearkit0005.jpg
http://img.photobucket.com/albums/v13/danga/rearkit0009.jpg
http://img.photobucket.com/albums/v13/danga/rearkit0024.jpg
http://img.photobucket.com/albums/v13/danga/rearkit0028.jpg
http://img.photobucket.com/albums/v13/danga/rearkit0035.jpg
http://img.photobucket.com/albums/v13/danga/rearkit0032.jpg
http://img.photobucket.com/albums/v13/danga/rearkit0021.jpg
The main thing is the kit is all the same height so it flows around the car. That was the hardest to get right.
I've also decided I may need a set of 16's...
Anyone got any alesios!
lol
http://img.photobucket.com/albums/v13/danga/rearkit0014.jpg
http://img.photobucket.com/albums/v13/danga/rearkit0013.jpg
colour wise I'm seriously tempted by glacier white with anthracite trim... saw a clio 172 sport with a v nice body kit on way home tonight in white with black gloss trim - looked stunning (for a frenchy mobile)
Jeff16v
09-05-08, 08:55 PM
The front is a work of art:thumb: . any decision on the final colour?
Was typing this as you were typing the above
Its like a baby calibra! :cool:
novacabrio
09-05-08, 11:24 PM
I think it definitly needs bigger wheels, something a bit differnt to theusual speedlines etc to go with the kit
Corsa C SRi items ;) very sqauresque, very angular :thumb:
shy witness
10-05-08, 08:15 AM
I think it definitly needs bigger wheels, something a bit differnt to theusual speedlines etc to go with the kit
i was just about to say something similar.....
with the car looking soo so differnet now............wheel choice will be vital wether the whole car works visually or not.:confused:
personally i'm not a fan of kitted cars.....but i doo like this......and all the effort thats went in is second to none imo.
it'll certainly need 16's or 17's on it.........but im not even sure if the old faithful speedlines would do the car justice.
i would be going through alot of photoshopped pictures of differnet wheels on the car ....before making any decisions ade:thumb:
great work though........i love this thread;)
vaughanmc
10-05-08, 10:39 AM
I'd have some new style Vauxhall wheels on there - Astra SXi wheels or Tigra wheels, something like that :)
I'd have some new style Vauxhall wheels on there - Astra SXi wheels or Tigra wheels, something like that :)
5 stud conversion and these prehaps?
http://www.autospies.com/images/users/Carboy/Carscoop_OPC_1.jpg
yeah weas thinking about those - whats the offset though? Didnt Vauxhall change their offset on the later models from et49?
i wouldnt know, sure a vxr forum would be happy to help :thumb:
DW-Nova
12-05-08, 08:08 PM
Looks brilliant mate! is it going to be done on the outside by PV show? going to take some doing! it is really coming together now and it looks all connected now if you know what i mean? as for wheels how about the renault wheels which i suggested a few pages back? sprayed anthracite with yellow paintwork would look ace, or sprayed black with white pearl paintwork would also look stunning, they look really modern and would look grate with the rest of the cars looks imo, but it's obviously upto you, glad you have decided on some bigger wheels than 15's though, they would have been swallowed by the car.
not going to be done by PV and I doubt it'll be done by the end of the year - wife's just been told shes got a new job over the other side of Scotland (Fife way) so we'll probably be moving in the next few months...
We're currently looking at taking on a renovation project with land and a HUGE barn. there's a garage (of sorts) with a work shop but it's really run down and I wouldnt put anything in it incase it falls down!
god knows what and where I'm gonna put the nova!
dude have to done any thing about towing eyes? just in case?
looks bang on mate!
mikey14sr
13-05-08, 10:48 AM
You have remembered the weight of the engine and gearbox will bring the front down arund 2 inches haven't you? lol
I dont think I've ever seen a nova without a twisted/warped boot lid, give it a bit of the old heave-ho, new hinge pins might help a bit too.
Matt2107
13-05-08, 01:03 PM
not going to be done by PV and I doubt it'll be done by the end of the year - wife's just been told shes got a new job over the other side of Scotland (Fife way) so we'll probably be moving in the next few months...
We're currently looking at taking on a renovation project with land and a HUGE barn. there's a garage (of sorts) with a work shop but it's really run down and I wouldnt put anything in it incase it falls down!
god knows what and where I'm gonna put the nova!
Four poster lift coming up?
scott.parker
13-05-08, 01:48 PM
Ade mate it's looking amazing! i dont know how you do it, i would of give up ages ago lol makes my table project look ****!
big gra
13-05-08, 02:22 PM
i can see a future feature car in pv mag!!
lol - dunno about a feature car in TV - would be nice...
Lj - towing eyes - yes I've considered them and will be making removable covers - need to get the masters of both front and back bumper as well as the side skirts sorted 1st. then I'll make molds, take copies and build the towing eyes and lifting points directly into the final items.
Mikey - Ive considered the engine weight and the front will be about 13cm (5") off the ground! So no high curbs or multi storey car parks for me!
Matt - still to convince the wife about a 4 post garage lift although she wants one of the huge aga type ovens for the kitchen so might do her a deal so we both get a toy each!
lol
Jeff16v
18-05-08, 09:42 PM
Great work Ade, if you are thinking about 5 studs maybe look at these.
http://cgi.ebay.co.uk/C20LET-C20XE-CORSA-TIGRA-NOVA-5STUD-HUB-CONVERSION_W0QQitemZ260240575037QQihZ016QQcategory Z10404QQtcZphotoQQssPageNameZWDVWQQrdZ1QQcmdZViewI tem
I was thinking.... If you got 5 stud:
http://cgi.ebay.co.uk/SAAB-AERO-ALLOY-WHEELS-WITH-TYRES_W0QQitemZ280227165387QQihZ018QQcategoryZ9888 QQssPageNameZWDVWQQrdZ1QQcmdZViewItem
-OR-
The new shape of this, smooth and with a twist in the spokes
http://www.genesis-tyresandalloys.co.uk/users/www.genesis-tyresandalloys.co.uk/upload/saab_after.jpg
EDIT: Ah, here (http://www.neobrothers.co.uk/product_info.php?cPath=23_254&products_id=372)
http://www.neobrothers.co.uk/images/1712786708_93_SC.jpg (javascript:;)
wisewood
05-08-08, 02:10 PM
AWESOME!!!!!!!!!
http://img.photobucket.com/albums/v13/danga/rearkit0028.jpg
Jim Mcrae
05-08-08, 05:43 PM
No updates then??
nah - cars "on hold" whilst I "tinker" with my White SR project I picked up just before PV. Almost finish most of the work - just a rear 1/4 arch and the underside on the passengers side. new vynal, possible respray to even everything out and its done.
the white ones my daily runner so I want it all sorted before winter kicks in.
The "puntova" will be worked on once the white ones done but tbh I'm prepared to wait till i move house and get my double garage - more space then...something I definately need!
Ade
loggyboy
18-08-08, 10:05 AM
Amazing work...
Skirts and lights look spot on. Not so keen on the bumpers, i think id rather see somthing closer to the orginal nova look. But still an great project.
what about this colour scheme ade? minus the flag decals, think dark grey wheels suit the colour:
http://www.autogaleria.pl/fotografie/renault/renault_megane_sport_f1_team_r26_2007_01.jpg
NASTYNOVA
18-08-08, 11:25 AM
mate thats amazin work!! if you ever get pulled, please take a pic of the coppers face when you tell him its a nova!!
dave - cant see the pic... link dont work. cheer for comments - nt to everyones taste but then that was the intention...
looks like a wild project!! the custom bumpers look amazing!!!
stunning car good work so far :thumb:
wow what a car. when do you think it will be done by. cant wait to see it when its done:thumb: nice work:)
NovaBoi92
02-09-08, 12:38 PM
when you getting it resprayed
Any idea when this project is going to get continued???
Pistol Pete
30-09-08, 09:10 PM
Just gone through the 74 pages of this! Lost for words! This project is amazing. Your craftsmanship is outstanding. When this car is finished it will be a credit to you. People attempt to fit different headlights to cars all the time, and fail on an epic scale. This is so different, attention to panel gaps, fitment etc is perfect. Cant wait to see updates of this. Good luck.
WOW
one of the best if not the best WIP i have read, pleanty of pics, good times.
i dont know where to start on commenting it, lost for words.
the body kit looks stunning, possible thought, the front flows nicely into the side skirts, then it doesnt excatly flow into the rear, maybe cut a groove in the rear bit if you get me can draw a pic if you like lol
the lights i wasnt keen on at the start but they are immense now, the front wing parts are amazing craftmanship. good welding for first attempts btw.
the bonnet, is amazing just is impossible to see once you primed it
the slam panel i was like its disgusting with all those levels, then you go and fiberglass it, looks top dog now.
i understand the attention to detail being a modelmaker my self. but this is something else, you are a Legendary Modelmaker/car builder :P
ok ok i think thats enough with the complaments, i think i have said enough
cant wait to see this finished:thumb::thumb::thumb::thumb::thumb::thumb: :thumb:
kenny_afh
23-10-08, 10:30 PM
remember seeing this ages ago, first class fit and finish has to be admired even if i dont quite know what it'll achieve.
also, just skimmed thru some of these pages so you might have wheels sorted but i couldnt help but think of these wheels...
http://img.photobucket.com/albums/v60/kenny_afh/IMG_2111.jpg
tony from roybacer had them a few years ago, no idea where they are now but i think they'd go with your car very nicely. diamond cut astra sxi rims i think they are...
novacabrio
23-10-08, 10:35 PM
those wheels pop up on ebay every few months
Daz9124
20-11-08, 11:57 PM
Im not a fan of kitted Novas but this is stunning, The effort and work thats gone into this is nothing short of amazing
I hope you have a good job if not you deserve one pal
Will follow this with interest
Your 1 hell of a talented man
any updates on this ade???
skidmarkz
20-12-08, 11:37 AM
just read this whole thread after seeing a link in your sig, OMG your talent is outstanding cant wait to see this finished. Your correct in saying it's not everyones tastes, but i personaly love it, just what the nova needed better lights lol :)
General Baxter
20-12-08, 11:42 AM
38 year old bolding middle age man, body kitted nova, brings a whole new meaning to boy racer
im only joking muffin lol
dj_wudgey
20-12-08, 07:19 PM
any moore progress on the sr mate??
Nova_Sean
08-02-09, 03:19 AM
Just followed the link on your sig.
Car looks sick mate. Any updates or news on her?
I had forgotten about this project... my bad
I have been looking at the side view piccys & I think the bottom of the arch lip on the front bumper needs moving slightly forward & the top of the rear bumper needs extending forward so it makes a more uniform arch shape
http://img.photobucket.com/albums/v13/danga/rearkit0035.jpg
but then I am crap at bodywork myself.
CoolTiger
09-02-09, 06:42 PM
just re read all the thread, an updates at all? doesnt matter how little still a update
DW-Nova
09-02-09, 07:51 PM
Yo, not checked back on this in along time ! whats happening ? remember you saying that you were moving house ? then again i havnt done anything to mine in along time, weather dosnt exactly help hey ! whats the plans in general ? looking forward to seeing some updates in future, great project !!
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