Joff's Nova Turbo Project

[draper]

at the risk of sounding like every1 else, ive just read this whole thread in 1 go, you're a star mate !! gave me some inspiration now, if i only do half a job compared to this ill be happy !! and i love the colour !!

[TommySR]

words cannot describe how detailed this rebuild is, absolutely amazing mate, hope to see this at PV show if its ready in time... great colour, great choice of wheels etc.. simply cant fault it.

[Benn]

http://www.elsamak.karoo.net/disc1a.jpg
hhmmm that pic makes me wanna do my inner archs,

[Adam Moran]

Stunning!!

Colour is sooo nice

Keep it coming ;)

[joff-turbo-nova]

Right All

I have a few days off and have finished off some more jobs.

Both front arches have now been Waxoyl undersealed which now shows black in the pictures. I have now
also waxoyled the insides of the chassis legs and front crossmember.

Also now finished rebuilding the front hubs replacing the bearings and using new CV joints.
The discs have been redrilled 4 stud and the Vectra GSI calipers have now been fitted with the M1144 pads.

http://www.elsamak.karoo.net/brake1a.jpg

Also sorted the tiebar out so it sits under the bottom arm in order to give extra clearance around the
end of the F28 six speeder.

http://www.elsamak.karoo.net/tie3a.jpg

I have also started fitting the new headlining. I have had this made up in the same way an OE headlining
is made so it has the gussets for the support bars. The material has been matched to the colour of the seats.

It needs stretching and trimming to fit around the apertures. I have started at the tailgate and have
completed both side windows fitting the grab handles along the way.

http://www.elsamak.karoo.net/head1a.jpg

http://www.elsamak.karoo.net/head2a.jpg

Just need to finish off fitting the headlining over the weekend and I can then fit the side and front windows.

Enjoy

Joff

[RJM25R]

Is that a new bonnet I spy????

[SPipower]

Lovely colour :thumb:

[joff-turbo-nova]

Rick,

The actual metal bonnet is new and has been provided by Cool Louvres as they have stamped 6 vents reversed to pull air in and placed directly over the air filter for that nice supply of cool air for the engine.

The other scoop is a hang over from the red version, a Sunny GTi-R direct replica with functional venting underneath.

The bonnet is currently absolutley filthy with a layer of dust and cutting paste so doesn't look its best!

http://www.elsamak.karoo.net/bonnet1a.jpg

The bonnet is due a respray as the base colour has cracked under the lacquer around the pressed in vents.

Joff

[RJM25R]

Well, i suppose a bit more work is nothing after so long.....

Any new pics of the dash? have you fitted it "in situ" yet???

Rick

PS I've just re-read the whole thread (lynn is watching ****ballers Wives and Dan is watchin football so I'm relegated to the computer!!) trying to find pics of the bonnet!!!! I forgot how many mega-pics there were shwing progress!!!

Could do with Admin puttin all the pics together in a thread, without idiots like me chattin on it!!!!!

[joff-turbo-nova]

I have a mate who is a web designer so should really get my own site sorted out - using a platform like novaload is easy one you have sorted the FTP side of things with your free space provided by your ISP.

I have c.25mb and I am up to the limit . I keep having to resize some of the pics in this thread so I can add more. I am now trying to keep the pic size below 100kb per pic so this is helping too.

I also keep a hi-res version on my hard-drive so if any one wants more details pics or if I have to query something in the future I have a reference.

I am just waiting for House to come on Ch.5 !!!

Joff

[Benn]

see you still have ya helper spring on your coilovers...have you tryeda rim over it to see if they clear?as mine and keiths didnt,rest looks great dude,

[hagger]

hey,

Just spent over hour and half reading this thread and loving the project so far!!think the colour is fantastic and may consider it for my respray!!!!i wondered if i could come see it some time as i live just outside beverley(i live in leconfield) cant wait to see it once its finished!!

Sam.

[krobinson]

see you still have ya helper spring on your coilovers...have you tryeda rim over it to see if they clear?as mine and keiths didnt,rest looks great dude,

Helper spring is only there to keep the springs in tight for MOT (i assume)

When i removed mine i noticed no change in handleing or ride quality. So if anyone has trouble with clearance, just take it out like me n benn did.

Keith

[shy witness]

absolutely superb rebuild.......1 that i could only dream about time and motivation wise

gorgeous colour.....extreme engine,and great attention 2 detail all add up 2 wot i would suspect would b 1 of the top nova's in the country :thumb:



keep up the good work mate:)


i'll admit i had 2 laugh at your every day job.........certainly not wot i expected at all....but well done all the same

[Mark Beeson]

looking good. What colour will it be or have I missed it??

[joff-turbo-nova]

Mark,

Colour is GM Europa Blue as per the Astra Coupe Turbos.

Nice feature on TV BTW, just out of interest which coolant rad are you running???

Cheers

Joff

[jamie gsi16v]

Mark,

Colour is GM Europa Blue as per the Astra Coupe Turbos.

Nice feature on TV BTW, just out of interest which coolant rad are you running???

Cheers

Joff

and mark what coolant rad fans are you using?

[Mark Beeson]

Std nova gsi mate cheers.

Everyone wants to know about the rad fans. Ive had loads of pm's

KenLowe ;-)

[joff-turbo-nova]

Progress has been a bit slow of late, just lots of work and family stuff going on!

Anyway, the headlining is now fully installed, all the windows and front screen are installed and the sunvisors are in.
Rear 1/4 interior panels are cleaned up and in situ.

I have trial fitted the corsa dash and have found that the EPAS motor sits extremely close to the back of the
fuse box so will need to spend some time re-routing some of the loom so things fit OK.

Also got my hands on a electrostatic flocking applicator and have given it a test as the dash is not ready yet.

I stumbled across a site in the US getting rid of some of their stock, and an Electrostatic Flocking Applicator
was amongst their stuff. Paypal payment later and 2 weeks shipping and my applicator arrived today in its own case :-

http://www.elsamak.karoo.net/app1.jpg

I am not quite ready to flock the dash yet but I needed to try it out on something - roll up the cadburys
highlights lid !!!! -


http://www.elsamak.karoo.net/app2.jpg

I then put the kettle on (you need some humidity for the applicator to work best) and then loaded up the
applicator and zapped the lid ......

http://www.elsamak.karoo.net/app3.jpg

The photo doesn't show the flock off to its best - the great thing is its a uniform layering with no clumps
and all the fibres are pointing 90 degrees to the surface which is how it should be. I'm really chuffed
with the results and it means I can do dashes, centre consoles, pillar covers .... well anything really!!!

Cheers for now

Joff

[hagger]

alrite mate, still aint got round to ringin ya been a bit busy lately! but hope i can still pop round sometime once i have less on!!hurry up and get ya dash flocked lol only joking should look smart as once done!!cant wait to see it once its finished!! keep up the good work!

[Benn]

very coolshould good cool when all flocked up,

[jedi]

how did u mount ur front trolley to ur carhttp://www.elsamak.karoo.net/bcc4a.jpg

[novamadman]

im guessing tca mounting points

[joff-turbo-nova]

Hi all,

In answer to the above, yes the dolly was bolted to the lower arm position in order that the engine bay
side of the lower arm bolt wasn't in the way of the paint.

Been on with the corsa dash today, trial fitted it again after rerouting some wires that fouled on the
EPAS motor - after some cable ties and soldering the problem was sorted! The dash fits fine now!

http://www.elsamak.karoo.net/cordash1a.jpg

Next I have been working on the centre dash to get the satnav concept sorted out. As I don't need
a DIN hole for the stereo (as the faceplate lives in the sunvisor) I have done away with this :-

http://www.elsamak.karoo.net/centre1a.jpg

It looks a bit rough and ready at the moment as its only just getting its basic shape. I am going to recess
the PDA behind the cente of the dash - which will flip forward for easy of access for security purposes.
I am going to mold out the semi-circle shape where the vents normally live and you need to remember
this centre bit will be flocked blue.

A lot more fibreglassing and filling required before I'm going to be happy me thinks!

Joff

[R1CH]

Looking good !
:thumb:

Rich

[Benn]

how much work was it fitting the corsa dash?

[Stanley]

http://www.elsamak.karoo.net/centre1a.jpg

Joff

erris that a pencil stuck in there lol

[novamadman]

lookin good joff

quick question --> where did you get the vinyl for the a pillar or did you just paint it??

cheers shane

[joff-turbo-nova]

Right,

I am now going to share a concept that I have been thinking about for the last 18 months.

Having seen some rather cool corsa dashes over the years I wanted to install one in the nova when
I did my rebuild. However I wanted to retain the digidash I was running in the mk2 nova dash.

However I had a thought, why not have a digidash for the passenger as well - just so that can see
what warp speed we were doing!!! lol

So I came up with a double dash concept which I have been working on over the last few weeks and
heres a couple of of pics!

http://www.elsamak.karoo.net/double1a.jpg

Also moved the hazard switch due to the centre console sat/nav concept

http://www.elsamak.karoo.net/double2a.jpg

Still needs a lot of work to get right , a fair bit of fibreglassing needed to get the levels on the dash right
and I will need to cover over the old screen vents and sink a new one in the middle.

Enjoy!!

Joff

[jamie gsi16v]

whatever next, well done joff!

[Benn]

joff, gen me up,how hard was it to fit the dash?was it alot of messing about?any prob with the heater wires?

[joff-turbo-nova]

joff, gen me up,how hard was it to fit the dash?was it alot of messing about?any prob with the heater wires?

See page 4 5 and 6 for how I had to hack the dash and column around to get the dash to fit - not for the faint hearted!!

http://www.novaload.net/forum/showthread.php?t=43066&page=4

[Timmy]

great work with the LET.
i saw you replace the back of the shell which is hidden by the rear bumper wear rust had got the best of it i have the same problem and i got small hole in the boot LOL was it a long job to replace that part of the boot and getting the patch part diffcault? so i know it vage but you post pics on page 2 in the middle

[Mark Beeson]

Nice thought of this myselp for a nova dash. Good effort. Will the wiring take the extra load???? Its always been said that a digi dash overloads nova wiring anyway. Most of the wiring would be easy but what about the speedo??

[joff-turbo-nova]

Nice thought of this myselp for a nova dash. Good effort. Will the wiring take the extra load???? Its always been said that a digi dash overloads nova wiring anyway. Most of the wiring would be easy but what about the speedo??

Most of the signals don't carry much power so should run two dashes OK without probs. As for the speedo I've just spliced into the speed signal wire from the gearbox transducer.

Time will tell if it works OK!!!

Joff

[BRoadGhost]

You could add a steering wheel for the passenger too.

[c'2.0lrt]

wow looking good wish i had the space and time for it,looking forward to seeing it finished? keep up the good work

[RJM25R]

What about a PC games steering wheel on the passenger side!!!

[Matt Pickering]

A steering wheel in the passenger side would be good just amagine passing a car at 70+ and taking two hands off the wheel to wave at em !1 they would poo their pants!

[novalovingned]

quality work,best i have EVER seen,r u going to go for some mag features when that beast is done,!


ned

[Mark Beeson]

Joff you probably already know but the transducer has a top mechanical output so in theory you could screw another transducer on top with separate wiring. Different dashes requires different pulsed transdusers

[jbowman]

Thats gonna be one crazy dash!! I hope you dont put another steering wheel in the passender side, say a Playstation wheel on the passengers in a Civic - looked pants!!

[craig green]

Hacking into a Lhand drive dash fascia might make the conversion easier for anyone else thinking of doing it

[jbowman]

Hows the flocking machine been going? Have you started any major flocking yet?

[Projectjordan]

http://www.elsamak.karoo.net/column2a.jpg


i've just noticed that the upper column appears to be the same as a Nova one, is this how your column was, or have you modified the two toghether?

cheers

Ryan

[_Ben_]

Craig,

Its a Bilstein PSS9 kit front and rear height adjustable set up.

Ben.

[joff-turbo-nova]

Things have been moving a bit slow - helps if you are not away on a residential training course
for a week - anyone for a teambuilding session??

Ryan- the column is how it came out of the corsa - no nova mods have been made - just seems to look
the same as the nova one!

I have now finished the centre console concept - it includes the heater and fan controls, intercooler
inlet & outlet temp readouts and the satnav. Pic :-

http://www.elsamak.karoo.net/console1a.jpg
http://www.elsamak.karoo.net/console2a.jpg

I have had to rethink the buttons and switches for the ignition, start, boot release, nos and fan
override - these are now going to live in a pod on the centre console just below where the ash
tray normally lives.

Talking of which the ash tray cover is now going to house the air temp / time / date readout
which normally lives on the top of the dash - pic :-

http://www.elsamak.karoo.net/ashtray1a.jpg

Also been fibreglassing the second pod cover to cover over where the steering column normally
comes out - this is still a bit rough and needs lots more attention . Pic :-

http://www.elsamak.karoo.net/pod1a.jpg

When I am happy with the overall fit and smoothness of the whole of the dash I am going to start flocking.
I will give the ashtray concept the first flock in blue just to see how it comes out, and if there are any
problems it isn't too big to rub down again!

Engine is away being rebored at the moment to accept the oversized low compression pistions so the cc
of the engine will be enlarged slightly . The crank is also being balanced and the flywheel is being balanced
and skimmed. I have been able to get a full refurb kit from GM for all the seals, gaskets etc and are
replacing the water pump and oil pump (a Z20LET item) so things on this front seem to be coming together.

Need to get in touch with Radtech to get an alloy radiator sorted for the engine cooling side of things.

Well thats about it - coming together nicely!

Joff

[novamadman]

cant wait to see this car finished

so much thought and effort going into it

well done m8 :thumb:

shane

[novaco]

gets better eveytime joff! well done mate!

[joff-turbo-nova]

Right .... been sorting this flocking business out!!

I have finished the ashtray which looks like this :-

http://www.elsamak.karoo.net/Ash1a.jpg

It then got flocked which looked like this :-

http://www.elsamak.karoo.net/Ash2a.jpg

And it fits in the dash like so :-

http://www.elsamak.karoo.net/Ash3a.jpg

Quite happy with the results so far!

Joff

[jbowman]

That looks cool, thats going to be one cool custom dash!

[Benn]

cool,

[valverguy]

I have just read all 31 pages for the first time... Im so impressed with your work... You have big balls my friend! I hope the progress continues..........and i get to see the finished car....

[c'2.0lrt]

looks good mate coming on nicely

[Wilson]

Just read this whole thread. looks well smart mate. goin to be a total minter when its finished. cant wait to see the finished project!

[DIB]

Excellent updates.keep them coming:thumb:

[Matt Pickering]

Your an insperation to us all mate! Can't wait to see it in the flesh !!

[The Simps]

I'm lost for words!

Any chance of being ready for PV? lol

Simps.

[Projectjordan]

great work joff, cant wait to see the whole dash flocked...

[joff-turbo-nova]

Regarding the dash I am awaiting some professional adhesive before proceeding further. Although the blue looks good it has started to shed fibres -not good!!!

I am awaiting delivery of some 2 part adhesive which is mixed with thinners to get the right consistency. This has a window of about 30 mins to get the flock applied which is much better, the adhesive lasts longer and is MUCH stronger.

Its very unlikely that I will make it to PVS as there has been a delay on the block rebore which now won't be completed until the end of next week!

No point rushing the project after all the prepwork so far!

Joff

[valverguy]

^^^^^^^^^^ agreed^^^^^^^^^^

[joff-turbo-nova]

Bit more work done this weekend.

I have finshed sorting how to connect the centre part of the dash with the satnav to the actual dash - happy with the way it now sits.

I have finished the pod for the passenger side and have now mounted the dash in situ to make sure it all fits before I start flocking :-

http://www.elsamak.karoo.net/dash6a.jpg

One problem - I was going to mount the buttons and switches for the ignition, start, nos and boot release on the centre console but there won't be enough room :-

http://www.elsamak.karoo.net/dash7a.jpg

So I am going to extend the dash a bit between the column and the centre section below the hazzard switch and put the buttons here :-

http://www.elsamak.karoo.net/dash8a.jpg

Also been working on a 3 gauge pod pillar concept - its getting there - needs a bit more filler and some more sanding but you get the idea . Its going to house my old guages from the red nova, namely oil temp/oil pressure on one, water temp on another and boost on another :-

http://www.elsamak.karoo.net/pillar1a.jpg

Enjoy

Joff

[novamadman]

looking great as usual joff

really cant wait to see the finished artical - any predictions?

shane

[novacabrio]

Havent read the full thread but whats going in the second pod on the passenger side? or is it a secret!!

[novaco]

Havent read the full thread but whats going in the second pod on the passenger side? or is it a secret!!

twin digi dash i think his idea was

[Tim]

twin digi dash i think his idea was

yup thats what hes going to do, hes an inspiration to us all lol

the passengers will be able to what warp fator they are going into, what with let, and the nos. Mental car that, cant wait to see it whan its done:thumb:

[shy witness]

serious work goin on there mate...........


and it should alll look good in the end..

willl b nice 2 see it finished....


and always worth a read anytime im online 2 see the progress

[joff-turbo-nova]

Quick update - just been to pick up some bits from the local chroming spot in Hull ..... enjoy!

http://www.elsamak.karoo.net/chrome1a.jpg

Had all the catches, wiper motor, bonnet catch, coil bracket etc etc done

http://www.elsamak.karoo.net/chrome2a.jpg

These are my 2 strut braces - one for the rear between the two wheel arches - the funny brackets are for the Nos bottle. The other brace will go between the B pillars and bolt into where the seatbelts used to go - this will hold my camcorder.

Cheers

Joff

[Benn]

ah chrome door catches...had mine done,re fill them with grease now cause they'll be really stiff to open and close!looks good tho!

[Matt2107]

Looking real good.

Is the dash very heavy with all that filler and fibre glass.

[RobMorris]

Sh*t the bed!

Dude, im off sick today and spending the last 1.5 hours has lifted my spirits!

You have just given me the inspiration to perform a whole restoration, missus wont be happy with that!

Keep up the good work...

Rob

[jbowman]

Shweeet! How much did the chroming cost for those bits? and how much prep work did you have to do to them before sending them to the chromers?

[draper]

just read this again, in the nicest possible way joff, your a fuking nutter !! that dash is crazy ! i was thinking about corsa dash's last night at work but youv'e just gone 1 step further (again) when you planning on having it ready for ?

think we should have novaload unveiling, all meet at joffs house for beer and cucumber sandwiches

[Jules]

think we should have novaload unveiling, all meet at joffs house for beer and cucumber sandwiches

You can't have a beer and cucumber sandwich! The bread will go soggy straight away!
lol

[joff-turbo-nova]

Here's a bit more flocking I've done tonight - the A and c pillars - the drivers side A pillar has also 3 guage pods grafted onto it.

http://www.elsamak.karoo.net/pillar2a.jpg

Enjoy

Joff

[Iain]

Making good progress :cool: Gonna be a beast.

[doherty]

absolutly*outstanding mate just read the whole lot start to finish an all i can say is WOW you got balls lol... fair play to you for doin most of the work yourself itll mean more to you when finaly finished

cant wait to see this completed:thumb: :thumb:







now were do i start to smooth my bay:cuckoo: :tard:

[Timmy]

Looking good joff, have to be honiest not a fan of the twein dash but still looks like one cool nova

[lee02]

ive read this whole thread mate and im inspired ive got a wrote off nova so im now intending to re shell it but i might have to do a full restoration including the shell youve proven that nothing is impossible even on a nova :) :cool: keep up the good work

[joff-turbo-nova]

As my engine is nearly ready to be installed - just got to rebuild it first - I thought I would get the gearbox situation sorted .

It was all covered in cr@p after 5 years in my nova -

http://www.elsamak.karoo.net/F28-1a.jpg

So set about stripping all the crud off with some gnuk type stuff and after a few hours work and some new gunmetal grey paint we have a nice clean ready to install F28 six speeder :-

http://www.elsamak.karoo.net/F28-2a.jpg

Also have been working on the shell to get all the runnin gear sorted. I now have a full working brake system including hand brake !!! The coilovers have been adjusted at the front to clear the tops of the tyres and we are ready for the flat bed - the wheels are my trackday set with Yokohama A539's :-

http://www.elsamak.karoo.net/wheels1a.jpg

Plan is to transport shell to my mates garage and put shell on a two post and raise up into air. Place engine and gearbox on a big box under shell. Lower shell onto engine & gearbox and do up the mounts!

Enjoy

Joff

[Mike]

OMG! Looking super shweeet that is joff! that car is going to be absolutley ****ingforking flawless when its done!

Top job!

[ajsvalver]

speechles a++++++++++++++++

[novamadman]

looking good as usual joff

cant wait to seeit finished

keep it up :thumb:

shane

[krobinson]

How did you mount your 6 speed mate? As it looks like you still have the standard nova mount on the chassie?

Keith

[shy witness]

lovely.....................i'm lookin 4ward 2 the end result

[jamie gsi16v]

How did you mount your 6 speed mate? As it looks like you still have the standard nova mount on the chassie?

Keith

just what i thort? i hadto chop move and weld my new mount on

[joff-turbo-nova]

Although the mount on the chassis leg looks standard ..... it isn't !!!

The original leg nearest the bulk head was chopped off and rewelded on the otherside of the leg (about 1.5 inches nearer the cross member) that was left in order to clear the bulk of the F28 box. A bespoke mount was then made up to connect the gearbox to a TAS group N rubber and the chassis leg.

Once its all installed I'll take some pics

Joff

[Mike]

Although the mount on the chassis leg looks standard ..... it isn't !!!

The original leg nearest the bulk head was chopped off and rewelded on the otherside of the leg (about 1.5 inches nearer the cross member) that was left in order to clear the bulk of the F28 box. A bespoke mount was then made up to connect the gearbox to a TAS group N rubber and the chassis leg.

Once its all installed I'll take some pics

Joff

Now thats a good idea :thumb: fair play for doing as most people wouldnt even think of chopping the engine mounts off!

[jamie gsi16v]

Now thats a good idea :thumb: fair play for doing as most people wouldnt even think of chopping the engine mounts off!
everybody chops the engine mounts off and moves them for the f28, we just didnt think joff had done this.

[Mike]

everybody chops the engine mounts off and moves them for the f28, we just didnt think joff had done this.

I mean just in general, not just for an F28, as in generally chopping of an engine mount, as you do!

[Timmy]

tissues plez LOL every time i see it it looks so nice, A.T.A?

[joff-turbo-nova]

You also have to remember that when I originally did the F28 conversion back in April 1998, there was only one other nova in existance with the F28 (Andy Windsors citrine yellow one) and he was somewhat tight lipped on how he fitted his box so it was a bit trial and error on the fitting, the linkage and the tiebar clearance issues.

Also it was only Courtney willing to help with the speedo problem and the fitting of the F20 speedo drive ring on the diff.

Having now looked at the kits available and other peoples ideas I would do what Rick Draper has done and weld a drivers side mount onto the passenger side chassis leg and make a bespoke mount to this.

Joff

[jamie gsi16v]

same way as mine, well done for doing it back then though joff shows enthusiasm (spelling)

[draper]

jamie, on a slight off topic - was you down netherfield sunday night ? sure i saw your car there

[joff-turbo-nova]

Quick update - not much really done as been on hols!

I have now flocked my central section of the dash in my nova - here's the results :-

http://www.elsamak.karoo.net/centre3a.jpg

http://www.elsamak.karoo.net/centre4a.jpg

Just need to flock the rest of the dash grey and were getting somewhere!!

Joff

[novaco]

looking excellent mate! whats going in seat wise?

[joff-turbo-nova]

Sparco Torino's retrimmed in alcantara :-

http://www.elsamak.karoo.net/WIP30.jpg

Front and rears are done and I just need the door cards and sunvisors sorted to match.

Cheers

Joff

[novaco]

nice!!!

[nov4801]

jesus christ!! lookin good mate, hope u get it done soon and keep the updates comin

[BigStan]

Wondered what had happened to this project !

Comin along nicely mate hope everything goes well !

[stuartp]

Looking good mate! You know every one's gona wont there dash boards flock once you've done yours!!

[Big_Chap]

alrght mate, how did you go about cleaning up the rear chassis legs? do you manage to do anything to the inside of them? and also, what did you use and do for sealing the underside after all the work?

cheers

[joff-turbo-nova]

alrght mate, how did you go about cleaning up the rear chassis legs? do you manage to do anything to the inside of them? and also, what did you use and do for sealing the underside after all the work?

cheers

Hi,

As the rear chassis legs had been waxoyled when the shell was new there was minimal rust on them. When I was stripping the underside I took the waxoyl & black underseal off with a heat gun. Sorted any rust and then applied 3 coats of black hammerite . I have then sprayed waxoyl into the chassis legs with a pipe attachment on my shultz air gun and have then sprayed waxoyl underseal on the outside to seal the bodywork up from the elements.

Hopefully should last a while as the nova will only be used from April - September and live in my garage for nights and overwinter.

Hope this helps

Joff

[joff-turbo-nova]

Another update ....

Radtech have been very busy for me making up a new radiator which has a thinner core than standard but higher density of vanes making it as efficient. This is so there is more clearance behind the radiator where the turbo lives as it is very tight in there!

Front
http://www.elsamak.karoo.net/Rad1a.jpg

Rear
http://www.elsamak.karoo.net/Rad2a.jpg

Some pics of my engine rebuild will go up next week - I am putting a Z20LET oil pump on the C20LET block and had a problem as the C20LET oil pickup pipe won't fit - solution a 2.2 Frontera pickup pipe which needs cutting and welding something like this :-

(NB This is Artfulmatt's engine of migweb)
http://img371.imageshack.us/img371/3544/img09464nq.jpg

Cheers

Joff

[Benn]

cool, love the rad,

[Mark]

How much did the rad set you back?

[Lee]

Nice rad, should reduce heat soak as well with a bit of luck!

[gary_126]

Fantastic thread, been watching for a while, but only just started logging on.

Im doing a similar full scale rebuild on my sri (not quite as mental as this)

look forward to more progress.

[The Simps]

Joff, where you planning on mounting your rad fan? front or back? which fan have you gone for?

Simps.

[Mark Beeson]

Twin 10"Kenlowe :-)

[joff-turbo-nova]

Hi,

I's using a Kenlowe fan (just one) which is mounted on this inside of the rad roughly in the same place as the OE fan i.e offset to the end nearest the passenger side.

Had it set up like this before I pulled the C20LET out and theres enough room to clear the turbo, manifold and gearbox.

Room is a bit time on the otherside due to the intercooler siting in front of the lower part of the rad , otherwise this would have been my preferred position as seen on Mark Beestons.

UPDATE ON WORK

Been dragged off to family doos and the cinema (to watch Pixars "Cars" - cool film - especially the wheel change at the end!!!)

Anyway just been tidying up the loom in the dash area, connecting up the alarm, screwing in the earth points, mounting the alarm sensors and sorting out the ducting to the front windscreen vent.

Once I'm happy with how all the wires are sitting I am going to reconnect the battery. When I rewired the loom I placed most circuits through the fuse box so I will reconnect fuses one at a time and see what happens!!

Got a GM 55ah battery which should be good for most situations!

Joff

[Mike]

to watch Pixars "Cars" - cool film - especially the wheel change at the end

Joff

What an ace film that is! :thumb:

[RJM25R]

Is this the most-viewed thread ever?
35000+hits!!!!!

[dave_rand]

ive only just noticed this thread i dont come on a great deal but im gob smacked ill be keeoping an eye on it now

[Mark Beeson]

Hi,

I's using a Kenlowe fan (just one) which is mounted on this inside of the rad roughly in the same place as the OE fan i.e offset to the end nearest the passenger side.

Had it set up like this before I pulled the C20LET out and theres enough room to clear the turbo, manifold and gearbox.

Room is a bit time on the otherside due to the intercooler siting in front of the lower part of the rad , otherwise this would have been my preferred position as seen on Mark Beestons.

UPDATE ON WORK

Been dragged off to family doos and the cinema (to watch Pixars "Cars" - cool film - especially the wheel change at the end!!!)

Anyway just been tidying up the loom in the dash area, connecting up the alarm, screwing in the earth points, mounting the alarm sensors and sorting out the ducting to the front windscreen vent.

Once I'm happy with how all the wires are sitting I am going to reconnect the battery. When I rewired the loom I placed most circuits through the fuse box so I will reconnect fuses one at a time and see what happens!!

Got a GM 55ah battery which should be good for most situations!

Joff

BEESON!!!!!!!!!!!!

[stv-b16a]

?

[Ash]

?

spelling - joff spelt it Beeston.

A

[stv-b16a]

oh.
thanks nova pilot

[joff-turbo-nova]

Mark ....... really sorry about the surname !!!

UPDATE :-

My car has a hearbeat ...... I have connected my new GM battery and without any fuses or relays it powered up OK - no fizzles, funny noises smoking or popping - very good news!!!

I am now in the process of checking each circuit on the fusebox. Done two - interior light (on one fuse) and the electruc sunroof which works OK (one another fuse) .

Need to start checking things like lights , brake lights, fog lights , wipers etc. This is where the fun begins tracking back any problems!!!

Joff

[Mark Beeson]

NO probs at all - Pissed last night!

[Stanley]

Mark ....... really sorry about the surname !!!

UPDATE :-

My car has a hearbeat ...... I have connected my new GM battery and without any fuses or relays it powered up OK - no fizzles, funny noises smoking or popping - very good news!!!

Need to start checking things like lights , brake lights, fog lights , wipers etc. This is where the fun begins tracking back any problems!!!

Joff

i had to do this on my mates SR.

had been sitting for about a year with no quarter window in it and damp had got the better of the electrics.

painstakingly tracing wiring/fuses etc etc till you find the problem.

most turned out to be corroded fuses but got there in the end (god bless electrical tape:thumb:)

keep up the great work mate, you deserve a fooking medal for youre attention to detail!

Top darts!

[joff-turbo-nova]

UPDATE :-

All the fuses are in and working . Both digi-dashes seem to be working OK without any conflicts yet!!!

Did have a problem with the wipers not wanting to work. Checked the motor with a remote power source worked fine. Checked the feeds from the stalks and relay fine bar 1 wire (green) Traced this back and noticed that the feed to the washer bottle motors was within the same circuit. Dug out the washer bottle, connected the motors - wipers now work on all settings HURRAY !!!

Need to source 3 x halogen bulbs for the digidashes as only 1 bulb out of 4 is working - a trip to vauxhall I think!

The alarm and immboliser system seems to be working fine as well , the microwave sensor is working (better than ultrasonics as microwaves aren't affected by wind or drafts) but the motion/tilt sensor seems to be non-functioning - a job for the weekend!!!

All indicators work , side lights, dipped and main beam, brake lights and fog lights (twin fog conversion on the clusters) - no reverse light to worry about!

After sorting the motion sensor I will need to look at wiring in some white LEDs onto a homemade board and mount them into the grab handle on the tailgate for number plate illumination as I have smoothed off the normal light place on the rear bumper.

Thats it for now.

Joff

[Ash]

cool, sounds like your really cracking on with it now, i take it the dash is fitted now then? any pics? (or have i missed that bit?)

Cheers

Ash

[5_door owner]

amazing work joff

the car has deffinatley come on leaps and bounds since i last saw it in your garage, finally sorted myself a worthwhile project aswell (http://www.novaload.net/forum/showthread.php?t=67066)

no where near as intense as yours, but not many projects are lol

your a TRUE nova enthusiast!!

keep up the good work and the updates :D

[dave_rand]

any new news

[joff-turbo-nova]

Been busy rebuilding my LET engine ready for installation at the weekend.

As I am using a Z20LET oil pump I have had to cobble together a new sump pickup pipe from a frontera one.
The Z20LET pump has a 20% better flow rate, sintered cogs and a larger bore pickup - done more for
reliability than anything else.

The bore was machined out to 86.5mm and the low compression JE pistions are in along with the uprated
rods and ARP bolts and a new set of shells was installed. The crank was reground and balanced
before installation.

http://www.elsamak.karoo.net/Block1a.jpg

http://www.elsamak.karoo.net/Block2a.jpg

I also checked on how close the pick up pipe is to the bottom of the sump. OE is approx 3mm and as you
can just see by this pick my new pickup pipe is about the same :-

http://www.elsamak.karoo.net/Block3a.jpg

Next job get the baffle plate , gasket and sump on and tightened up (I'm using an 8v sump gasket as these
seem less likely to leak), then get the block onto an engine stand to put the head and inlet manifold on and
all the cams and belts and tensioners etc.

Block is going in from underneath once bolted up to the gearbox (and new clutch) - I am borrowing a mates 2
post lifter so I can lift the whole shell up , position the engine , slowly lower the shell down and do up the
mounts! Well thats the theory anyway!!!

More pics to follow at the weekend

Joff

[craig green]

Sounds good Joff. To think you wanted to debut this at PV...

Engine build sounds fun. In from underneath is best though.

Can we see a pic of the dash's?

CG

[DIB]

sounds good. look forward to the engine in pics

[Mark Beeson]

Looking good. The dash bulbs are pricey though I warn you. Have a fiddle with them. A bit of K J normally does the trick lol if you know what I mean

[Adam]

Do you need mk2 astra gte digidash halogen bulbs?

I cant read most of the thread as pics take too long load on 56k,Lol.

[joff-turbo-nova]

I have already sourced some halogen bulbs from Vauxhall - Mark you were right at ?3 plus vat each NOT cheap!!!!! About ?12 for 3 !!!

I tested the bulbs with my multimeter on ohms and all 3 were open circuit - i.e the filament was broken.

Rounding up all the engine mounts, bolts, driveshafts, clutch and gearbox tonight as the shell is being collected by my mate Andy Friday morning on the back of his recovery truck and being transported to the same garage as where the shell was sprayed to use one of their 2 post lifts to get the shell up and then back down over the engine & gearbox.

Not planning on connecting much up just the three mounts (obviously) and the drive shafts and then get it transported back to my garage at home where I can work on it at my own pace and standards.

Joff

[stuartp]

Out standing work there mate!! I like that little sentance at the end "Own Pace And Standards" Keep it up!!

[joff-turbo-nova]

Right I can only describe yesterday (Saturday) as ...... a little dissapointing to say the least.

Anyway here's what happened ......

Got the sump on the engine and turned over the block to start working on the top end.
As you can see a nice Z20LET oil pump in situ and some nicely honed bores!

http://www.elsamak.karoo.net/Block4a.jpg

Anyway , next job was to bolt up the flywheel . I had already sourced new bolts from Vauxhall
and all was going swimmingly until on the final tighening sequence on the bolts (15 degrees)
one bolt decided to snap !!!!! Not good. Got the bolt out of the threads but tried all of the local
bolt places and Vauxhall and all were either out of stock or not stocked at all !!!!

http://www.elsamak.karoo.net/Flywheel1a.jpg

This now gave me a problem - without a bolt I could not finish the flywheel, or mount the clutch
or put the gearbox on or put the whole unit in the nova :mad:

Also I was changing the core plugs as upon inspection of one they were rusting from the inside out.
Out of the 7 (3 on one side and 4 on the other) Vauxhall had kindly supplied 2 odd sized ones so I was
two short - another reason for non-installation!

So in the true Dunkirk spirit I sorted out some more jobs as far as I could go - firstly get the studs in
the block ready to put the head on .... nice shot of the forged pistons in the bores -

http://www.elsamak.karoo.net/Block5a.jpg

You can also see on this pic right at the bottom below the starter motor where I have had a
flange welded onto the sump and its been drilled and tapped out ready for my mechanical oil temp sensor.

It was then on with the head which has been pressure tested, all the valves recut into the head
and slightly skimmed to get a nice flat surface for mating with the block and gastket (which is a
steel Z20LET affair). Cams were also placed in situ (which are Courtenay reprofiled jobbies).

http://www.elsamak.karoo.net/Block6a.jpg

You'll also note in this pic in the background some nice Japanese metal - namely a Subaru Impreza -
spec unknown - and a just off the import boat last week Nissan Skyline with a nice RB26 engine -
its got a problem with a bearing on one of the two turbos!

Also hanging around on the premises was another just imported RX7 with some very expensive
suspension and wheels :-

http://www.elsamak.karoo.net/RX7a.jpg

And also the garage owners Mitsubishi Evo 8 which is one of the limited edition ones with extra tweaks
under the bonnet - he's also said I can borrow it for a weekend sometime ...... oh YES!

http://www.elsamak.karoo.net/Evo1a.jpg

So the upshot of the the whole morning was this .....

http://www.elsamak.karoo.net/Waiting1a.jpg

Shell waiting for an engine looking a bit sad :cry:

Well should have all the missing parts rounded up next week so should be installed next weekend! Whats a week !!!

Joff

[macc nova]

the nova looks the sadest but the best at the same time:thumb:

[RJM25R]

Joff , new wheels??

[joff-turbo-nova]

Joff , new wheels??

Rick,

Sort of ..... just have a set of Astra SXI 16" with Yokohama A539 for track/strip action :p and my Wolfrace Voodoo's with Michelins for show / normal road use. :cool:

BTW I like your wheels - pushing the boundrys of being different !

Joff

[Adam]

I have already sourced some halogen bulbs from Vauxhall - Mark you were right at ?3 plus vat each NOT cheap!!!!! About ?12 for 3 !!!

There are mega expensive from vauxhall, i managed to get a few from a local motor factors tho for ?2.69 each, inc Vat :D :thumb:

[Novasport]

http://www.elsamak.karoo.net/RX7a.jpg

Rx7 looks nice and clean, always wanted one of these. Had a mk1 about 10 years ago. How much is that one up for & whats the year & mileage?

[joff-turbo-nova]

Not too sure on the RX7 - I'll find out the spec, year, mileage and selling price if you are interested and I'll PM you back next week. The car is in East Yorkshire.

Joff




http://www.elsamak.karoo.net/RX7a.jpg

Rx7 looks nice and clean, always wanted one of these. Had a mk1 about 10 years ago. How much is that one up for & whats the year & mileage?

[RJM25R]

Rick,

Sort of ..... just have a set of Astra SXI 16" with Yokohama A539 for track/strip action :p and my Wolfrace Voodoo's with Michelins for show / normal road use. :cool:

BTW I like your wheels - pushing the boundrys of being different !

Joff

Cheers:thumb:

[DIY*VALVER84]

if you crash this you will be the worlds biggest cock face monkey ****er going. please dont destroy it! im inspired joff,makes me want to start mine all over and do it all properly lol. all the best with what work you have left. look forward to seeing you at the shows.
scott.

[Mark Beeson]

if you crash this you will be the worlds biggest cock face monkey ****er going. please dont destroy it!

COCK FACE MONKEY ANKER - Whats one of those????????lol

[joff-turbo-nova]

Right then..... I have taken the opportunity whilst my shell is out of my gargae to get round to flocking the dash - hurray.

Prepped up the dash with a wipe down with white sprit, then got the atmosphere nice and humid with
a couple of kettles (electrostatic application works a whole lot better with humidity) and got the dash on
my workmate....

http://www.elsamak.karoo.net/dash7a.jpg

I then got on with the business of flocking and after lots of adhesive, flock and some application we have this ....

http://www.elsamak.karoo.net/dash8a.jpg

http://www.elsamak.karoo.net/dash9a.jpg

http://www.elsamak.karoo.net/dash10a.jpg

The pictures don't really do the flocking justice - its looking good ! Oh and I need to have a tidy up in my garage!!

Joff

[shy witness]

that looks a neat job u FLOCKER.................



great attention 2 detail in this car.......cant wait too see it fininshed

should b gorgeous

[SRlew]

looks good mate! keep up the good work!

[dave_rand]

might sound daft but what is this flocking all about

[bump]

might sound daft but what is this flocking all about
1) It helps to reduce light reflections from the dash.

2) It hides the joins and filler work that has been done by Joff.

[Spudly]

can someone change joff`s username to GOD please lol, nearly 38,500 views is this the most popular thread one here ever??
Joff everytime i read more of your updates im astounded, i would say keep up the good work but there really is no need to lol, i really want to come see it in the flesh sometime, you know my mate brodie from hornsea dont ya?? would like to come next time he does or if not before if the offer still stands,
there is a lad with a mk1 SR from leconfield who would love to come see it too if your open for visits sometime, cheers looking good!!!

[chimp007_uk]

thats flocking awesome lol

sorry... that really does look good. this is going to be one sweet nova!

[joff-turbo-nova]

i would say keep up the good work but there really is no need to lol, i really want to come see it in the flesh sometime, you know my mate brodie from hornsea dont ya?? would like to come next time he does or if not before if the offer still stands,
there is a lad with a mk1 SR from leconfield who would love to come see it too if your open for visits sometime, cheers looking good!!!

Hi, when my shell is back come over with Broady and your other mates and we'll kick some tyres!!

Joff

[hagger]

im loving your work joff!!this is one mint nova and a half!! cant wait till you finish this as its gonna be sooo nice!! keep it the good work fella!!
Oh im the lad from leconfield with the mk1 SR LOL!

Sam.

[Spudly]

Hi, when my shell is back come over with Broady and your other mates and we'll kick some tyres!!

Joff

YES PLEASE lol, jus let us know when ya dont mind an there will be an orderly (honest) que of novas down your street lol

[joff-turbo-nova]

Right, quick update .... just a bit of mincing around today as I am still awaiting some parts on back order with GM.

Got all the flywheel bolts sorted and torqued up which mean I could put the clutch and cover plate on .....

http://www.elsamak.karoo.net/Engine1a.jpg

Also put the starter motor, water pump and back plate on along with all of the timing belt cogs , cam cogs and bottom pulley.
Just need to time everything up!

http://www.elsamak.karoo.net/Engine2a.jpg

Also here's a better pic of the adaptor plate in the sump for the mechanical oil temp probe for my racetech oil temp guage
which will be mounted on the A pillar along with the water temp and boost guage.

http://www.elsamak.karoo.net/sump1.jpg

Should have the inlet manifold and alternator back on mid week and hopefully the car will be transported back to my garage
next saturday where I can start plumbing in all the coolant and inlet pipes. :confused:

Joff

[fearless]

Even using special tool KM666 (I thinks that the number) to set belt tension !!! - you don't do things by half do you !!!


Dave

[Benn]

very cool dude,getting excited yet?

[joff-turbo-nova]

Actually starting the engine is a while off yet ...... but it feels as though things are finally coming together!!

Dash is now hanging from my garage ceiling so its out of the way and doesn't get knocked - the flocking has come out very well indeed - just need to sort out the centre console and I can start sticking the interior back in!!!

Job for this weekend however is tidy the garage up so I can see the top of my work bench!!

Joff

[c'2.0lrt]

wow mate i take my hat off to ya! thats spot on like the dash looks good.

[joff-turbo-nova]

Been just prepping up some bits tonight for the engine :-

Camshaft cover :-

http://www.elsamak.karoo.net/Camcover1a.jpg

Hope you like the carbon plug cover !

Cambelt cover (sprayed Europa Blue and also a carbon one) :-

http://www.elsamak.karoo.net/Beltcover1a.jpg

Engine should be installed in a few days - pics to follow

Joff

[cheshiresport]

Very nice gear there mate

[RJM25R]

HHmmm, where'd you get the carbos spark cover Joff??

[joff-turbo-nova]

Rick,

Got the bits off a guy from migweb a couple of years ago - JackosNovaTurbo was his username - lived near Middlesborough.
Heres a link to one of his threads :-

Carbon fibre parts (http://www.migweb.co.uk/forums/vauxhall/styling-wheels-interior/52127-carbon-fibre-goodies.html)

Did some good stuff then did a runner and disappeared overnight with a load of peoples money (not mine for a change!) about 2 years ago.

Got a spark plug cover, cambelt cover and the turbo inlet manifold cover all carbon then lacquered. Very strong and
immensely light !!! Can understand why the guys in F1 use it everywhere!! Shame really - I should have also got
a rear grab handle, an exhaust heat shield and a tailgate interior trim panelbut wanted to see what the quality
was like before spending loads. Before I had chance to order more bits he'd done a runner!


Couldn't say who now would be able to supply these??? Courtenay / Regal at a price worth half a house ????? no doubt .
I think I paid about ?25 for the spark plug cover and the cambelt cover and inlet cover were about ?40 each. Bargain!

Sorry can't help further!

Joff

[joff-turbo-nova]

Rick,

Just had a dig around and I remember speaking to these guys a while back :-

Fibre-lyte (http://www.fibre-lyte.co.uk/cf/index.html)

They seemed to be up for making most things suggested - I was after a panel to cover up the boot lip between the two plastic side covers and they basically said bring along what you want making in carbon - they would take a mould and then make as many as you wanted - bigger the order lower the cost per item.

Joff

[novacabrio]

Rick,

Just had a dig around and I remember speaking to these guys a while back :-

Fibre-lyte (http://www.fibre-lyte.co.uk/cf/index.html)

Joff

This link should carry a warning, Danger do not enter unless you are prepared to spend alot of money. Now to look at what I can get!!:thumb:

[RJM25R]

Cheers Joff, I remember now. He was makin a dash binnacle(shroud) as well wasn't he???

[craig green]

That Jackson guy was pretty much up for making anything.

I remember rear quarter trim panels (OE shaped), door cards & boot trims, bonnets, dash parts etc & XE belt covers etc etc.

Shame he's done one. He could still be raking it in. ?$

[joff-turbo-nova]

Another frustrating Saturday ......

All was going well got the gearbox mated to the engine block ..

http://www.elsamak.karoo.net/Engine4a.jpg

However when I came to get the cambelt on and time up the engine I found that the water pump that I had installed
came from the square toothed version of the engine - I need the semi-circular type ..... grrrr! :cry:

Tried a few local factors .... all said can get one for monday/tuesday ..... which really wasn't much help!!!!

So just bolted on the engine mounts, stipped off all the cogs and pulleys and pulled out the wrong pump
and came home !!!!!! :mad:


http://www.elsamak.karoo.net/Engine3a.jpg

So will now wait till correct pump arrives before attemping installation. Yes I know you can get the pump in
and out (just) with the block in but its a hugh pain in the rear to do so I'd rather wait a few more days and
do it the easy way!!!

Joff

PS This thread is now through the 40,000 views number - cool!

[novacabrio]

when you expecting to have the engine in?

[joff-turbo-nova]

Hopefully in the next 7 days - its just the water pump holding me up now!!

Joff

[craig green]

bummer

[mikey14sr]

after I pulled the blown 1.3 apart I realised I had the wrong pump on it, luckily for me the belt wasn't on long enough to snap but it was rather worn!
Is that alternator brand new? the pulley looks extremely shiny.

[joff-turbo-nova]

HI,

The pulleys are new from SBD :-

http://www.elsamak.karoo.net/WIP31.jpg

They run a BMW sized belt and the bottom pulley no longer has a rubber insert.

Original pics are on page 2 of this thread :-

Page 2 (http://www.novaload.net/forum/showthread.php?t=43066&page=2)

Cheers

Joff

[Rick Draper]

How come you have gone for those pulley's? They are only used on high reving XE motors to stop the alternator overcharging the battery. To my mind you would have been better getting a courtenay bottom pulley and running a single v belt.

[novacabrio]

eta = ????? I really don't want to rush this project - hoping for the back end of next show season to be realisic -
it would be nice to get it ready for April 2005, but I think this will be a bit unrealistic!

Joff


:thumb: lol thats the type of speed I like

[cheshiresport]

April 2005??? Sounds like my timescales!!! though Joff has done an amazing job so far

[joff-turbo-nova]

How come you have gone for those pulley's? They are only used on high reving XE motors to
stop the alternator overcharging the battery. To my mind you would have been better getting a courtenay
bottom pulley and running a single v belt.

Rick,

I'm using the multi-v belt primarily due to past problems with the normal single v belt coming off the pulleys
when either doing quick starts from the lights or going up the drag strip, which was a bit annoying!! Don't know
exactly why it happens as I run the TAS solid mounts.

Its going to be fun finding belt - all I know that a BMW one will fit - which one - who knows!! I'm going to measure
the length of the belt required with a bit of wire and then nip into Halfords and have a measure. Multi-v belts handly
have the length stamped on them!!

On the build timescales I try not to rush things - they get done when they get done!!! At least I don't stress
out about missing deadlines!!!

Progress on work - whilst the shell is out of the garage I've got the carpets out for a clean - they have come
up fine with a vax but one big problem - the car they came out of had a dog with white hair - how do you get
animal hairs out of the carpet fibres??? It won't hoover out, or vax out and my clothes brush ain't much cop either??

http://www.elsamak.karoo.net/Carpet1a.jpg

Any tips or ideas would be appreciated!!!

Joff

[ade]

you can get dog hair removers - theyre like a roll of sellotape with a very sticky backing - try that.

masking tape is also pretty good...

[Martin]

nice1

[novacabrio]

wire brush

[novaco]

wire brush


^^^^:thumb:

[snoPPy_dogg_uk]

this is lookin to be a very nice nova be great to c the finished product

[Brodie_Sri]

Hi joff good to see the car is coming on! Try useing a wiper blade to get them dog hairs off. Brodie

[Spudly]

Noooooo dont use a wire brush you`ll kill the carpet, im a valeter and we use hoovers with the thin nozzle type ends, you will find that if you rub the nozzle across the hiar both ways it will usually move one way, then just carry on going that way and it should stroke free, takes a while though, if not rubber gloves can work by just stroking across the carpet but they get hot though so be careful lol, good to see youre not the type to stress about little mishaps, after all the time and work you put in, a few more days wont hurt, im sooo looking forward to seeing this car, before and after its completed, err whats you gonna do with your evenings and weekends when you finished it though lol!!!

[novanutted]

thats sum project m8,looking to be 1 hell of a minter:D

[mini_kris]

WOW just read this thread from start to now its taken me over 2 hours and be weel worth the read, hats off to you joff your project is an inspiration!

[Matt2107]

, err whats you gonna do with your evenings and weekends when you finished it though lol!!!

Start another one :D

[5_door owner]

looking good joff,

the hairs in question are actually my cats :eek: that thing malts all day everyday lol

coming along nicely, carpets cleaned up rather nice :cool:

p.s my cat wants her bed back lols

[novaboyopr]

looking wicked mate getting along very nicely. can wait to se it done

[Adz The Rat]

Just spent ages readin this and my hat goes off to you.
You have done some fine fine work there and had some great ideas.
Cant wait for the next update

[craig green]

for removing cat hair etc. I just wrap duct tape round my hands (sticky side out) & then roll it back & forth over the carpet.

[joff-turbo-nova]

Success !!!!!

We now have an engine installed again after 3 years of being separated they are back as one unit!!!

Anyway ..... got the water pump in and all the pulleys back on, cambelt on and tensioned and ensured that the engine was timed up correctly!!!

It was then craned over to a two post where my shell was waiting , heres a snails eye view of the underside of the shell on the ramp ...

http://www.elsamak.karoo.net/Install1a.jpg

With engine positioned correctly under the shell we pulled the engine through with the crane being carefully not to catch the bodywork!

http://www.elsamak.karoo.net/Install2a.jpg

I then got the mounts lined up and tightened so it sat in the shell correctly ...

http://www.elsamak.karoo.net/Install4a.jpg

I then bolted the suspension back on and put the wheels on and ....

http://www.elsamak.karoo.net/Install5a.jpg

And one newly installed engine and F28 gearbox in the bay (with lots of wires looking messy that need sorting) ....

http://www.elsamak.karoo.net/Install6a.jpg

And all finished ready to roll onto the back of the recovery truck for the trip home - car is now back in my garage where
I have the task of pumbing everything back in!!!!

http://www.elsamak.karoo.net/Install8a.jpg

Big cheers to Andy at Bridlington Care Car for the lend of the ramp, rescue truck and general brute strength getting the lump in!!

Enjoy

Joff

[Timmy]

what a love job that car looks so cool from unnder neath, ETA on it now joff? that engine looks a treat with that big gearbox looks a right pig to fit and move about.

[Lee]

If mine comes out looking half as fine as that ill be pleased! Top work chap!

[Phil GTE]

Hi - Assumed you have noticed the tie bars aren't evenly installed.


Minta of a project though - good to see such high standards set.

[joff-turbo-nova]

Hi - Assumed you have noticed the tie bars aren't evenly installed.


Minta of a project though - good to see such high standards set.

Phil,

To get the tie bar to clear the end of the F28 gearbox you have to mount the tie bar under the lower arm (as opposed to on top in the OE application).

10/10 for observations though !!!!

Joff

[mini_kris]

looking good

[dave_rand]

any update?

[focus_neil]

Truely awesome work gone on there.

This will be an increadable car when finished, gives me inspiration to work on mine tonight

[krobinson]

we need an update :)

[jon boy 22]

Awesome mate very nice car

[DIY*VALVER84]

update... is she breathing yet?

[Pillar]

just been reading this for 2 1/2 hours (45 pages) wot a motor an absoulte one off good work mate keep us updated

[joff-turbo-nova]

Chaps,

Sorry for the delay in updates but its been a bit hectic at work and I needed to take some time out to help the wife decorate :( !!!

Anyway normal service is now being resumed....

As you know the engine & gearbox is in and I am now in the process of sorting out the gear linkage and
problem with the alternator pulley catching the inner wing.

The gear linkage is a bit of a pain as I have had to use a couple of rose joints and getting everything lined up
for all 6 forward gears is getting to be a pain. There is also to much play in the ball joint cups on the old nova
linkage so I am investing in some newer gearlinkage parts from a corsa off ebay and hopefully this will solve
some of the problems. I spent 3 hours Sunday playing with the linkage and it still doesn't work .... grrrrrrr !

The alternator pulley situation has had a more positive out come. I was trying to use the pulleys as seen here :-

http://www.elsamak.karoo.net/WIP31.jpg

These use the mutli-v belt which is considerably less likely to jump off the pulleys at high RPM. One problem
- the multi-v pulley was less than 1mm from the chassis leg - not really a viable option.

I then contacted a mate who gets his dad to knock up alloy pulleys to make up a set (top and bottom) with a deeper
single V which will hiold the belt a lot better.

Here's the bottom pulley :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/pulley1a.jpg

And here's the clearance between the alternator pulley and the chassis leg , close but about right for a nova 16v conversion!

http://i2.photobucket.com/albums/y15/joff-turbo-nova/pulley2a.jpg

Once the gear linkage situation is sorted I can then start on the pipework around the engine and then carry out
the final head torquing sequence.

Cheers for now

Joff

[kronk10]

didnt really understand thatlol but fooook me this is one hell of a nova and its not even finished yet

[novashed]

is that the guy off astra mk1 forums joff? making those pulleys

[joff-turbo-nova]

is that the guy off astra mk1 forums joff? making those pulleys

Yep, chap called Graham , lives a couple of villages away from me. Currently rebuilding his C20LET into his Mk1 Astra . He put a couple of rods through the side of his block a while back and is rebuilding his engine to a similar spec to mine!

He was just doing bottom pulleys but I asked him if he could look at top ones and hey presto a week later we're sorted!

Joff

[Benn]

wish i had the clearance on my alt :(

[krobinson]

What did you do to your linkage before joff? As you ran a 6 speed before.

Keith

[Ben]

I hate sorting the linkage on Nova's wether it be a Turbo or a 1.0l there just a pain.

Great work as ever, any ETA on the finished product Joff?

[joff-turbo-nova]

I have sourced a new quick shift linkage from Rally Design.

Problem is that the top link bar no longer reaches so have had to put in some rose joints and threaded bar. The plastic sockets that hold the ball joints on the end of the linkage are all cracked and keep popping out - all in all a bit of a pain.

I am sourcing a corsa linkage to have a play with which should help.

ETA on finishing - probably Feb/March2007 .

Got all the wiring sorted for the dash - its also got a carpet in as well now!!! (I Know I get excited about rather minor things but it hasn;t had a carpet in since Feb 2003 !!!!)

Dash should be going in sometime shortly once i have sorted the pipework for the side vents.

Joff

[craig green]

Sounds good. Coming together inside.... creature comforts & all (carpet).

Someone needs to source these plastic, ball retainers for the linkages. GM no longer stock them & all the ones Ive found have gone brittle.

[Martin]

Joff Its lookin good mate.. but is that a hole i spy in the chassis leg? what happend?

[joff-turbo-nova]

Joff Its lookin good mate.. but is that a hole i spy in the chassis leg? what happend?

Do you mean this ????

http://i2.photobucket.com/albums/y15/joff-turbo-nova/pulley2b.jpg

[joff-turbo-nova]

These bits arrived today :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Roose1a.jpg

Silicone hoses from Roose Motorsport - arrived within 24 hours!

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Autovaux1a.jpg

Some hard to source bits from Autovaux in Wakefield - arrived within 48 hours of order.

Joff

[Martin]

ohhh lol oki dude my bad

[krobinson]

These bits arrived today :-



Silicone hoses from Roose Motorsport - arrived within 24 hours!



Some hard to source bits from Autovaux in Wakefield - arrived within 48 hours of order.

Joff

Got some of the turbo long copper nuts when i was last in wakefield. Autovaux really do rock! How much were the silicon hoses joff? can they make the same in black? like the way they come with the ends attached so you can bolt directly to the turbo. Mint

Keith

[Dose]

Hi mate just spend a good 2 1/2 reading the whole thread top job made u deserve a reward for all ur work...suppose wen its up on the road its gonna be a reward on its own...will be looking out for this next show season wen i am down..

chris

[barkeybooster]

joff, did you spend some time on the EPS unit yet?

[rc]

this man is an apsolute legend! 47000 views speaks for its self! just spent well over two hours reading through the whole tread! wot a man!
reading through has given me so many ideas id of neva fort of in my life (although had concidered the twin digidash's for quite some time lol)
and to find he is not even in the motor trade, he's a finanual advisor, adds miles to his credits!
really cant wait to see the final product finished, looks like its really takin shape!

bottom line, this really is a 56-reg nova!

WELL DONE THAT MAN!! :thumb:

[liam_ere]

wow this guys amazing lol i agree with rc 56 reg indeed. so whats going on now can we have an update please joff:D


liam

[joff-turbo-nova]

RE :EPAS

Been looking into a extra ECU box which lets you adjust the assistance it give manually. Found one on ebay for ?110 which is expensive, but cheaper than the Harry Hockley kit which is ?200+

http://i12.ebayimg.com/02/i/08/e1/64/06_12.JPG

Link is here :-

Ebay EPAS control unit (http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=330058026815&ssPageName=ADME:L:LCA:UK:31)

Been working on getting the gear linkage right which is taking time!!

Joff

[The Simps]

Hi Joff,

Been looking into doing the EPAS conversion while mine is off the road. Having obviously played about with it fairly extensively, in your opinion would the system fit with a normal mk2 nova dash? I'm gonna guess that maybe the fuse box would need relocating??

Simps.

[joff-turbo-nova]

Best person to speak to about this would be Martin Kelson - he's running the Epas with a mkII dash so would be able to give some more info as to what is needed and where you need to move stuff!

His user details are here :-

Martin Kelson (http://www.novaload.net/forum/member.php?u=9783)

Also found a guy from Northern Ireland selliing EPAS control units that will vary the assistance - like the Harry Hockley kits but a lot cheaper . For one unit its ?110 - Harry Hockley charge +?200 !!!!

Joff

[Kev Turbo]

need pics of the rose motorsport hose kit on the engine!

hurry up!!! LOL

[The Simps]

Cheers for that Joff.

In regards to the variance problem - http://www.migweb.co.uk/forums/vauxhall/mechanical-electrical/289991-corsa-b-epas-column.html?highlight=EPAS

3rd post down, Nova Turbo (Rob isn't it?) has used the digidash sender.

Simps.

[gossy]

car lookin gd looks like a lot of cash an effort has gone in to this lookin reall gd cant wait to see it finished if it is not alredy finished how much does it cost to get a gd spray job an to rbild an engine keep up the gd work love ya car its a minter
thanks andy

[krobinson]

Going to run EPS on mine too. Will be trial fitting it before sending the shell off.

You need to secure the motor to the bulkhead too with a metal strap as with the force it moves the whole unit.

Keith

[joff-turbo-nova]

Quick update .... been a bit busy in the run up to Christmas so not much really has happened!

Since the 25th I've managed to finish off the gear linkage which is now a hybrid of Nova / Corsa C and Rally Design quickshift. It took loads of tacking testing and repositioning to get right - but I now have all 6 forward and reverse gears - hurrah!

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Linkage1a.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/Linkage2a.jpg

Also sourced a larger 60mm o.d tophat that can also run the turbo cover (wanted to keep that as I have a carbon fibre cover) ...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Tophat1a.jpg

However the outer lip was quite a large step for the charge to pass .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Tophat2a.jpg

So I got the die grinder out and smoothed off the lip .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Tophat3a.jpg

Also sourced from Roose a 60mm to 50mm reducer which will work with the new tophat ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/60mma.jpg

Working more on the engine tomorrow

Joff

[Kev Turbo]

great work buy why have the 60mm tophat then reduce it staright down to 50???

prob a reason behind it but just curious?

more pics needed loving this thread!

[joff-turbo-nova]

Been busy sorting bits on the engine today.

Got the fuel rail on, wiring loom onto the injectors, throttle housing and gear linkage set up.

Also tried sorting the micro-switch for the NOS system. First attempt I mounted it here :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Mirco1a.jpg

However then realised I had not put in the throttle cable bracket so had to scrap that idea and come up with a different solution ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Mirco2a.jpg

Just need to hook up a fuel supply to the fuel soleniod and the supply line to the NOS soleniod and the Nos system is almost sorted as all the wiring is already in place!


great work buy why have the 60mm tophat then reduce it staright down to 50???

prob a reason behind it but just curious?

more pics needed loving this thread!

The reason is more for practicality - I was previously using 50mm pipe and I have shed loads of 51mm Samco hosing so it seemed a waste to not use all this stuff.

Joff

[craig green]

congrats on the linkage. I would guess at that being a proper bitch to get all 6 forward gears & reverse satisfactory.

[Kev Turbo]

fair one mate,

i have a 50mm tophat if you want that as im after a 60mm one, its been powdercoated blue too!

seems a shame to waiste the extra diameter that i am after

[joff-turbo-nova]

Been busy today finishing off the Nos installation.

First job get all the piping in the right place. Took a T out of the fuel line from the pump - there was already a handy join in the pipe so just T'ed in here ...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Nos5a.jpg

Next job was to get the soleniods plumbed in and wired up and mounted and here they are .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Nos1a.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/Nos2a.jpg
Also needed to tap a hole into the tophat to mount the nozzle ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Nos3a.jpg

Needed to make sure it fires in the right direction - i.e into the engine and not back up to the intercooler!0

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Nos4a.jpg

Finally this is how the engine bay is looking - lots of tools and a bit of a mess!!!!

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Engine5a.jpg

Next on the list after New Year is wire up the back of the block (alternator & starter motor) and then start plumbing the water and inlet pipes.

Joff

[Paul]

As always looking, good a very interesting on goin project:thumb:

[Stanley]

Strut-tops are the ultimate tool-chest haha

Looking FOOOKING awesome as always man!!

Top Darts!!:thumb:

[Novasport]

These bits arrived today :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Autovaux1a.jpg

Some hard to source bits from Autovaux in Wakefield - arrived within 48 hours of order.

Joff

You think those manifold nuts would fit an eight valve exhaust manifold? Be good to use with mine as they would be easier to fit to prevent damage to my nickel plated manifold.

[Novasport]

Kieth might be the best man to try it ;)

[rc]

Strut-tops are the ultimate tool-chest haha



a quote from anyone who's ever worked on a car engine lol




top job, gets better with every pic, who'd of thought that some one could make a C20LET with no's look factory in a nova!

[joff-turbo-nova]

You think those manifold nuts would fit an eight valve exhaust manifold? Be good to use with mine as they would be easier to fit to prevent damage to my nickel plated manifold.

Can't see why not as they fit standard sized manifold studs. I'd get some now as they seem to be getting harder to source I am led to believe :confused:

You will need a long 7mm allan/hex socket to tighten them up.

Joff

[nova---chris]

Excellent work joffy lad. Looking real smart.

Thanks for the info on the epas ecu mate. Its all up and running mint now. Infact makes me want to drive the car now lol!

Anyhow keep up the good work pal. hopefully see it later this year :thumb:

[joff-turbo-nova]

Quick update, been off work for a week with a nasal passage infection - not pleasant. Anyway back to work
tomorrow and as I have been feeling tip top today I have been busy sorting some jobs out.

Got a replacement pipe (from Roose Motorsport in blue silicone) for the back of the water pump and also the
pipework that lives under the inlet manifold. WHAT A JOB getting access to these!

Anyway after a lot of grunting and moaning I have got them fitted :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Backpipe1a.jpg

Also fitted the coil, header tank and sorted out a bit more wiring loom :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Pipe3a.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/Pipe4a.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/Pipe5a.jpg

Just need to remember how all the pipe go together!! lol

Joff

[Mike]

oooh looking mint as always Joff

cracking on i see top man

[mikey14sr]

You weren't out in this today were you joff? Just I saw a nova in the same color heading towards Brid this afternoon, going at a fair turn too, just past Lisset.

[joff-turbo-nova]

Nope - not me - engine hasn't turned over and fired yet!

Joff

[joff-turbo-nova]

Got a bit busy today - first of all I needed to know where the water pipes from the turbo would go - so I needed to mount up this little turbo technics jobbie :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Turbo1a.jpg

However the intake pipe has a rather large lip on it so off it came . Here's a pic with me just starting the smoothing off with the die grinder :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Intake1a.jpg

And after a bit of grinding we have ended up with this :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Intake2a.jpg

It was then on with the fitting and getting all the pipes to attach to the various parts and getting the turbo to intercooler pipes sorted and here we are :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Bay1a.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Bay2a.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Bay3a.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Bay4a.jpg

Next jobs are getting the next 2 tighening sequences sorted on the head bolts - get an equal length driveshaft sorted and plumb in the guages.

Cheers

Joff

[kevster]

looking good bin reading this post for 3 hours lol like the work gone in to her

[ChampagneSuperNova]

lol same here, been reading this for god knows how long, really interesting, some great stuff going on, cant wait to see her all finished. I think you should post in r49's post on "how much have u spent on your" lol.

Keep up the good work mate!
Craig

[krobinson]

Nice work Joff, cant wait till i get to that stage!

My turbos off for a stage 1 hybrid, and i need a new actuator for phase 2, what type have you used joff? and where did you get it?

Keith

[joff-turbo-nova]

Keith,

The turbo is a recon hybrid unit from Wallace Performance (well actually they just get Turbo Technics to sort it out for them).

The actuator came with the hybrid turbo unit so I assume it will be up to the job of holding some extra boost. Time will tell !

Also noticed on the Turbo Technics box when the turbo was delivered - 30.06.2003 ! Good job the turbo was in a sealed bag and had pleanty of oil slopping around!

As to total cost so far - due to the length of time taken - coming up 4 years I wouldn;t want to add it all up! Most of the cost has gone so far on things like the engine rebuild (rebore, low compression pistons, uprated rods, different oil pump, full set of gaskets & seals, cylinder head refurb, new turbo, new clutch, new alloy intercooler and alloy rad), the interior has taken a bit (purchase of some Sparco Torinos - retrim in alcantara) - EPAS steering - corsa flocked dash - new ICE install (still in my spare room!) . Suspension is now Bilstein coilovers and all the suspension has been powdercoated and of course the respray in Europa Blue.

All adds up but over 4 years doesn't seem too bad!

One another topic - has anyone got a spare oil cooler sandwich plate that has the thermostatic valve in it as I need a sandwich plate in with the valve - the one I have doesn;t have this valve as I was just running my guages off it in the previous incarnation!

Cheers

Joff

[Big_Chap]

think you can get them from rally design (if its what i think you mean, oil-stat?)

[krobinson]

Cheers for that Joff - Spoke to universal turbos today and they are fitting an uprated actuator to mine too. Should have it back in a week or so :) Will probably lay in a box somewhere for a few years lol

Keith