CG's rebuild thread. PROJECT COMPLETE

[craig green]

Chassis legs are now solid, although not all that pretty after all the past repairs & now turreting etc happening on them.

Beam should look nice when done, bit of a pain to degrease it. The years of muck & oils etc seem to be resistant to all the degreasers & cleaners I have here.

Might take it for blasting me thinks.

I went to a SW drag racing event yesterday, there was a handling circuit which the quickest car most of the day was a 2.0 8v Nova running twin carbs. Sadly he broke an engine mount & a Clio 182 took the top spot from him.... pics to follow & a vid of said Nova if it worked out. ( I held the cam above my head & hoped for the best!)

Also spotted a couple nice Novas in the queue for dragging incl a Red mk2 SR with PNGCLUB.COM stickers...

[peester]

^^ mehhhh - bit off topic CG..

Blasting sounds good; - might diminish any feelings off 'not-up-to-scratch-ness' about how uve done the underside, with a blasting..

[craig green]

Yep, think I'll have it blasted. I'll get a quote tomorrow as I used to be able to do it myself for free so wont appreciate being billed for it tbh...

Meh. Its my thread. LOL

http://www.pngclub.com/forum/showthread.php?p=764062#post764062

[craig green]

I dropped the rear beam off for blasting & coating over a week ago, so with a bit of luck I'll have it back soon. Then the joy of putting the new bushes in.

[novacabrio]

You fiiting standard bushes or pro flex etc? Use a Threaded bar and wind them in, dead easy

[craig green]

I've got new std GM bushes here, but I'm tempted by some split type Rally Design ones for ease of fitting.

Still no news on the beam though. Slow at shot blasting this geezer. No wonder he's cheap!

[GRUNT 16V]

get some poly bushes !!

[craig green]

True! Fr end is rosejointed & polybushed, so it seems crazy not to really.

I dont see how it can make a massive difference though tbh. New GM bushes will be a big improvement over old tired ones & the coilovers are stiffer than a stiff thing anyway. I'll see what money I've got spare prior to reluctantly buying Xmas presents for the family etc......

[GRUNT 16V]

Easier to fit !!

[craig green]

Cant be any harder than putting Polyrace ones in the fr tie bar brackets!

[craig green]

If anyone is interested...

Collected the rear beam from the blasters today. 2 weeks late.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/DAKOTA_DRAG028.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/DAKOTA_DRAG031.jpg



I minced about after work drilling holes in the Astra GTE fuel pump cradle, to make it fit on Nova chassis legs.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/DAKOTA_DRAG033.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/DAKOTA_DRAG032.jpg



After tea I headed over to my parents to borrow my Dad to help me ( I helped him) put the bushes in the beam.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/DAKOTA_DRAG034.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/DAKOTA_DRAG035.jpg

I also put 2 coats of Gloss black on the fuel tank straps. And some seam sealer underneath at the back panel. no pics.

[Ash]

Beam looks minty! Is it powder coated? I didn't know you ran rear discs either.

What's the idea with an Astra bracket then?

[Adam]

Beam looks a top job.

[peester]

oooooooof.. sir.

[krobinson]

Looking good craig! Good work once again!

Keith

[craig green]

Cheers guys. I've found some motivation from everyone encouraging me...

The Astra fuel pump cradle is merely being used as I sold my old pump & Nova cradle when I was breaking the car. But the Astra one has the rubber isolation within the bracket, not up against the chassis leg vai the fixing bolts, so essentially it mounts to the car more solidly. No difference tbh.

The beam is just 2 pack Black. Seems durable enough.

Rear discs are new to this build stage of the car, likewise the 288mm fr discs & Corsa servo.

[Jeff16v]

Good work there, beam looks good. PV08 then?

[craig green]

PV08 then?

Lets not get ahead of ourselves! lol

Yeah beam does look nice I thought.

I was running over things in my head last night, I feel major progress is only a few days away now. Literally bolting on lots of bits, rather than slaving over rusted old stuff.

Tempted to have the shell blown over at some point too. Mainly roof, bonnet & bumpers tbh.

[AndyGSi]

This is a cracking looking car - some excellent work gone into this!

[GRUNT 16V]

Under way again then!!!!! thank god!!

[krobinson]

Its Achieveable craig.

Make a list, get that list done, make another and so on. I've started to do that and its really helped.

Keith

[craig green]

Under way again then!!!!! thank god!!

Yes, the desire to give you a small block whooping has helped. lol

I kinda do that anyway Keith, I struggle to stick at one job though.

Thanks; AndyGSi.

[craig green]

Pic showing the paint on the tank straps.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/dscn2239.jpg

[Plug]

Looking good craig

[craig green]

No pics today but there should be some decent progress to write about next week.

I've spent the last few evenings finishing off the Red on the underneath.

The fuel pump fittings are in, so the pump is easily mounted.

I've retrieved the ball from the tank that should be in the anti-over flow device. So the sender has been sealed back on.

New cotton braided tank hoses ordered from Vauxhall.

Tank is basically ready to fit into position if it werent for some wet paint last night. Then the fuel lines will go back on.

[BIGS]

sounds like your cracking on with it. bet its cold working on it at this time of year tho

[The Simps]

Can't beat this xams hols for making a bit of progress...

[Mike]

Liking those tank straps Craig, im in the progress of making some stainless steel ones up :D

[craig green]

sounds like your cracking on with it. bet its cold working on it at this time of year tho

Funnily enough NO. lol My garage is under our flat & does seem to suck some warmth from our living room. I was in the garage on Friday night until 1:00am & was actually really hot & down to just a T-shirt after a while.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build011.jpg

[Mike]

Im liking the look of that Craig :D

[joff-turbo-nova]

Funnily enough NO. lol My garage is under our flat & does seem to suck some warmth from our living room. I was in the garage on Friday night until 1:00am & was actually really hot & down to just a T-shirt after a while.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build011.jpg

Craig,

Don't know if you were aware but the original GTE tanks had a bitumen type substance in a long strip that was located under both straps.

However unsure whether this was just for sound deadening purposes or to stop the tank moving around - just make sure its nice and solid and doesn't rub anywhere!

Looking good

Joff

[craig green]

Thanks for the heads up Joff. I havent cleaned off any of that bitumen like stuff you mention. On my tank it was all on the upper surface against the tank/underside of the floor pan.

Heres a pic of the filler neck in place.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build014.jpg

[craig green]

Where the filler neck joins the tank.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build015.jpg

Fuel pump & its cradle mounted onto the chassis leg.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build016.jpg

Next little job is putting the metal fuel lines onto the floor pan & connecting various ends with hose clamps & lengths of rubber pipe. I need a new length of hose from the tank to pump though. GM only part IIRC.

[Austin_Nova16]

Looking mint under there craig. Nice work!

[Martin]

Looks great fella

[Adam]

Nice work, looking cool.

[vaughanmc]

Looks smart with the underside all painted up, when do you think it will be finished? :)

[krobinson]

Its looking very very smart now craig! I bet your chuffed with the results! Your not too far off finishing it now, keep the motivation up! :D

[craig green]

Thanks guys.

No idea when it will be complete tbh. Hoping to step up a gear with the progress now (after new year). Obviously I dont want it being completed too close to shows etc for the sake of giving it a good shakedown & a few hundred miles under its belt before heading to the Nurburgring etc...

[peester]

good update. showing true colours now..

[dan23]

do you have any before an after pics of the welding that was done to the rear end / chassis legs ?

[blue_peg_16v]

coming along mate looks very nice

[craig green]

dan23

These dont show much other than how crusty she was.
http://i30.photobucket.com/albums/c323/turbocraig/RustyNovaPics/2ndpics002.jpg
http://i30.photobucket.com/albums/c323/turbocraig/RustyNovaPics/2ndpics003.jpg

Ready for turret to be slotted in.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Turret_1.jpg

Showing the turret in with a large plate over the side of the inner arch/leg box section.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Turret_6.jpg

Should have some more updates & pics later this week. Quite motivated at the moment.

[craig green]

Couldnt leave such filth on my thread.

Look at the comparison?

http://i30.photobucket.com/albums/c323/turbocraig/RustyNovaPics/2ndpics002.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build014.jpg

[greg1.4]

nice wee nova craig..think i have told you before too.

[craig green]

Cheers! Some good progress last night (wednesday).

I sorted the final puzzle in the jigsaw of fuel pipes, just the feed to the pump which is a 12mm size hose, the Walbro pump has a smaller fitting on the inlet side compared with the OE GM pump's & the outlet from the tank. I was sold a series of adaptors from the hydraulic supplier where I got the fuel hose from but I ended up cutting down some of the smaller hose with a knife & making a sleeve to fit inside the 12mm hose & got it to work.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress052.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress051.jpg

Next up I wanted to get the fr GSi seats out of our spare bedroom, so bolted them upto the subframes. I had to raid the odd M7 bolts from my stash of spare bumper bolts. The Recaro's can wait for now as I need some custom fabrication to get them low enough on Nova subframes.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress049.jpg

Next job was to assemble the hubs & rear discs etc back onto the rear beam. I've decided to try some thin spacers between the back plates & stub axles on the 2 front most mounting holes to induce a bit of 'toe out' & see what that does for the handling of the car. Novas are very neutral when it comes to the road holding so I'm hoping this might liven up the back end a little.

After the beam was prepared, I lifted it into position & bolted it up into the mounts & fixed bolted up the dampers.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress056.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress058.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress059.jpg

I did have a concern over how close a tyre would run to my fuel pump & bracket as it was not a Nova item, no concerns there when I quickly stuffed a wheel on. Nice to see a wheel back on the rear after what seems like ages of staring at a bare floorpan at the back.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress060.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress061.jpg

Only needs a new exhaust hanger welding to the chassis leg & I'll be putting the rear bumper on & it will be starting to 'look' finished soon. (pics to follow)

[Adam]

Sounds like your cracking on :)

[craig green]

Yep. As I posted on MIG. I'm terrified of missing PV etc.

Really cracking on now. Just picked up some copper brake pipe for the beam, pipe ends for calipers & some M6 bolts for the rear seat fittings.

Back out to the garage tonight....

[SRimon]

Still got my old Speedlines for it Craig?

[Mike]

Sounding good Craig :D youve been making some good progress *awaits pics*

As for missing PV, ive not accepted that fact that mine aint gonna be there at all lol

[craig green]

*Pics added for yeserdays update*

managed to put the gear linkage in place after a quick clean up & put jubilee clips on a few coolant pipes. I'm using all new clips for reliability & aesthetic reasons. I find greasing the threads enables them to tighten up easier/further & means they dont seize over time. Genuine 'Jubilee' branded clips btw

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress043.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress048.jpg

[Timmy]

looking good,

[craig green]

Thank's Timmer.

Just buggering about making copper brake lines up for the rear beam & the short ones from the master cylinder.

[craig green]

Made the decision 2 buy some handbrake cables yesterday. Went for a RH Nova cable (long) & after looking at the book chose a mk2 Cav LH (short) cable. People have mentioned welding some studding in at somewhere or other & with these cables offered into place & the yoke/connector lobbed on, I just need to weld on a length of M8 stud to the threaded length on the end of the Cav cable. With the yoke came the end of the last cable, 5 inches of M8 stud. Nice.

I went to scrapyard this morning for the cable yoke, thanks to a T reg Corsa I found the least corroded yoke with the 2 rubber sleeves still intact. I also got an induction hose for the AFM to TB from a diesel astra but have actually got a new one coming from Vaux. A pir of OPEL boot badges fell into my toolbox aswell.

Then I went to our local rally spares place (AC Services) & was given a cone filter to try (dusty old Pipercross thing) & some advice about braided brake lines. He can do me a new K&N for 29 quid +VAT which I thought was good.

[craig green]

Blimey! This slipped back to page 6 in only 3 weeks of inactivity....

Anyway. I have an operational handbrake. Been wiring in starter loom & battery cables etc behind the block. Bought a battery box, heavy duty cabling & a distribution mount for battery to be mounted in the boot.

I've got the K&N filter I ordered above, Received the Cav diesel inlet hose, fuel pump wiring has been stripped back from the loom & renewed. Hoping to tid up some odds & ends & get her ready to turn over whenever I get a new battery & some fuel in the next week or so.

Nova-boy-roy to the rescue next Sunday, to weld the fr end too.

Things are happening but too busy for pics!

[Martin]

nice1 mate get cracked on :)

[Adam]

Have you tried the diesel inlet hose Craig, does it fit?

[craig green]

Yes mate fits a treat. Not cheap at ?46 though. Only buy it once I suppose.

Last night I drilled the holes for the battery box & screwed that in with nice stainless bolts & wing nuts.

[Andy_L]

Looking forward to seeing this on the weekend, will provide me with some inspriation I reckon.

[Adam]

?46? Fooking hell lol

What model was it off? The NA diesel or TD?

[craig green]

Cav TD. I've got one from an Astra mk3 TD, but is slightly different. Still suitable if you want it?

Will need funds to go towards the ?57 I've just been quoted for std rubber brake flexi's from a local factor!!! WTF? !

[Adam]

I was quoted some mental price for rubber flexis too.
So i fitted GoodRidges, which were cheaper lol

[craig green]

Aye it might have to be Goodridge braided hoses. I'm trying to track down some MOCAL ones as they are far nicer IMO, but cant seem to track any down. In which case I'll get hold of some Goodies I spose.

[Ash]

I seem to remember paying about ?3 for a front brake hose.... I could get you a price from work if you want?

I might be selling my Goodridge hoses soon tho, if I go for full braided. Just goto work out the costs.

[craig green]

I was thinking of doing fully braided Ash.

Cant get my head around all the fittings etc, seeing as theres no guide & all the websites offer you the stuff assuming you know what you need. I could have a lengthy phone conversation about it but cant be a$$ed tbh.

[craig green]

Spent all day yesterday having some welding carried out on the car. Grunt16v (grant) did the work for me, top welder that boy. Really pleased with the results. It looked like it was going pear shaped for a while, what I thought was a small patch turned out being a pretty major hole (fecking car!). Anyhow all done dusted & etch primed. Thsi means I can crack on with more stuff over the next week or 2.

Thanks again buddy.

[Mike]

Sounds like your steadily making progress Craig :D

[SRimon]

Where did you find the rot Craig?

Thought you had it all sorted at Si's that time?

[Martin]

any pics craig? :)

[craig green]

Si's welding is utter dirt mate, dont get me started on that!

There was a patch on the fr chassis leg (under fr arch) that Si neglected to do for me. I found a hole in the sill under a skirt fin, which upon closer prodding ended up taking out the whole corner of arch & sill area & finally Simon never replaced the exhaust hanger when he did the chassis legs.

Just glad I've met a talented welder atlast. Maybe I'll find a good shell for keeps one day & have a decent shell for the future. I'm under no delusions that this is a good shell... It just looks alright on the outside. LOL

[craig green]

any pics craig? :)

NO both cameras in the place were deaded, I got one pic mid progress but tbh was busy making cups of tea & watching for fires. LOL

I'll sort pics this week of the work that has been done. I've obviously got to go around with the Grey stripe & proof all the welds & patches with underseal & paint etc.

[edit] was good seeing the old girl parked out in the winter sun all day.

[Martin]

kool yeah i was like that when a mate did the welding onmy 1st nova..

"ermm is smoke ment to be comign from there?!" lmao...


was there much welding that needed doing? cant rememebr now?

mine need a fair bit, check my WIP lol its just as bad as my 1st one

[SRimon]

Hmmm surprised to hear that, any work he's done for me has been good in the past :)

Looks like the underside of yours is a bit of a patch work quilt, will be good to have it finally all sorted and patch up, which should see it in good stead for a fair few more years whilst you sort out finding that exceelent shell :)

I mentioned it before but didn't see a reply, you still gonna use my old Speedlines?

[craig green]

Like I say Si, I shouldnt really go into it & talk it out with him but I dont regard plates that are only spot welded in place, edges of plates not welded & general blow holes & poor welding not ?400 quids worth of fabrication tbh. Yes my car is rusty as feck, if it was too far gone he could have told me or refused to continue.

Anyway onwards! Yes speedlines will be going on. I have some GSi slabs in satin Black to use for track days & general abuse.

[SRimon]

Good man, your car always looks awesome on speedlines ala you avatar imagine ;)

Not far off now tho Craig? If you were a smidge closer I wouldn't mind giving you a hand.

[craig green]

Cheers for the offer mate. Should be going to some meets in it perhaps by the summer.
Now the fr chassis leg is welded, I can paint out the arch & put the fr bumper on, so thats another step towards it beginning to look done, likewise the rear bumper can go on now as the exhaust hanger is welded on. Some things have to wait for other stuff to go on. (as you know)

I'm going to book off some holiday I think to help me crack on with it a bit....

[GRUNT 16V]

Hi bud glad your happy with the handy work!!!!! looking forward to see it finished!!!!

[belly257]

just noticed this thread awsome project mate:thumb:

[craig green]

Hi bud glad your happy with the handy work!!!!! looking forward to see it finished!!!!

Yeah well happy, cheers mate. I've treated all the welds & plates in UPOL seam sealer & started to coat over all of them in Red Hammerite to match the rest of the floor pan & inner wheel arches. Had the back box (exhaust) temporarily hung last night. Position is spot on for the hanger & it looks mean. :D

[Riggy]

I'm going to book off some holiday I think to help me crack on with it a bit....

lol i was checking dates in work before for myself doin the same thing lol :thumb:

[craig green]

I havent had any time off yet this year. Could do with a break from work tbh. Though that doesnt really happen in my line of work. I have to do all the work in adavance for the time I'm off. So end up being stressed as a coont before I go, meaning I NEED the time off even more so.

Just bought some batteries for my digi-cam anyhow. Progress pics to follow.

[dan_cf40]

nice work mate ive gone the same way with my brake servo
how did you go about brake hoses thats how far ive got an got put off

[craig green]

Brake lines will be happening any day now. Just ordered the braided flexi's & will set about running copper lines when they arrive. I threw out all my old hoses & pipes (doh) so dont have the fittings etc to use as a reference.

Only jobs I sorted over the weekend was a little more painting of the welded areas & attached the alternator & starter trigger wires etc at the back of the engine block, aswell as some finalising of my alternator tension adjuster.

[edit] the cheapskate HYUNDAI batteries I bought at the 'pound shop' are good for approx 2 digi-pics per pair! How laughable is that?

[SRimon]

[edit] the cheapskate HYUNDAI batteries I bought at the 'pound shop' are good for approx 2 digi-pics per par! How laughable is that?

I'm really not suprised!

ETA yet Craig?

[craig green]

No ETA. Need to run all the necessary pipes & hoses through the firewall (needs drilling) then the inlet can be bolted back on & I'll buy a battery & fill with some fuel for cranking over.....

Couple weeks no doubt.

[SRimon]

Awesome, March PNG meet? gooo on

[craig green]

Would never have the money to tax, MOT or insure it sadly.

Those are the issues I'll have to look into after its built. MOT it & then see where I'm going froim there.

[Adam]

[edit] the cheapskate HYUNDAI batteries I bought at the 'pound shop' are good for approx 2 digi-pics per pair! How laughable is that?
pmsl lol


I have all the union etc sizes written down somewhere from when i replaced mine, will see if i can find it :thumb:

[Adam]

Right:
Rear Disc/Drum to Axle x2- Both ends M10 unions
Nearside Rear line- One M10 Union, One M12 union(MC end)
Offside Rear Line- Both ends M10 unions
Nearside Front Line- Both ends m10 unions
Offside Front Line- One M10 Union, One M12 union(MC end)

So you need 10 M10 unions, and 2 M12 unions by my calculations.

Bear in mind i have the standard nova MC etc, so i dont know if the corsa mc has the same size unions, i assume so tho.

[craig green]

Cheers Adam. Great help.

The Goodridge lines will be here tomorrow (I'm told), ''overnight parts from Japan'' LOL.
Just nipped out & had a new power loom made up at THE BATTERY CENTRE* for the alternator & starter feed as I butchered it drilling one of the terminals out to 8mm.


* THE BATTERY CENTRE is a fantastic little shop in my town that sort out all matter of electrical gremlins, rebuild alternators & starters etc & generally do car electrics. Often for pence! I love them.

[craig green]

PICS.

If you are eagle eyed you'll spot the plate behind the seam sealer. Its a large plate covering a couple rust spots that were cut out, we figured a large plate would look better than a couple smaller ones. Seeing as the chassis has a multitude of Hockley plates anyway, it looks right at home.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build035.jpg

Heres what was lurking in its place before we ground it out & set about re-strengthening the 2 panel skins & plating over.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/rustyLEG02.jpg
Pretty ugly I think you'll agree.

The rear edge of the passenger sill where it meets the arch lip had gone pretty crusty too. This turned out way worse than I had banked on & wasnt too impressed when Grant cut it out into a rather large fist sized hole. Nicely patched back up from about 4 separate peices of steel though. The underside was made concaved too, in order to avoid the side skirt fin sitting proud.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/SILL-REPAIR.jpg


Heres the exhaust hanger Grant welded back onto the rear chassis leg. I figured an M10 hardened steel bolt would be stronger than a strip of steel, so the head was ground off to leave a tag for the exhaust rubber to sit against. Almost looks factory!

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/ZORSTHANGER.jpg


Lastly a couple pics of the battery box I've installed in the boot.

Lid off;
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/BATTERYBOX01.jpg

Lid on;
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/BATTERYBOX02.jpg

Mounted down with stainless fasteners & wing-nuts underneath.

[Adam]

Nasty bit of rust there.Good to see its all sorted now.
Nice job on the backbox hanger.

[craig green]

Just had the phonecall to collect my Goodridge braided brake lines from AC services.

'Overnight parts from Japan', living upto their name.

[Martin]

nice1 craig/grant lol

[craig green]

Aye. Grant is a star! (GRUNT16V) on here.

[dan_cf40]

Brake lines will be happening any day now. Just ordered the braided flexi's & will set about running copper lines when they arrive. I threw out all my old hoses & pipes (doh) so dont have the fittings etc to use as a reference.

Only jobs I sorted over the weekend was a little more painting of the welded areas & attached the alternator & starter trigger wires etc at the back of the engine block, aswell as some finalising of my alternator tension adjuster.

[edit] the cheapskate HYUNDAI batteries I bought at the 'pound shop' are good for approx 2 digi-pics per pair! How laughable is that?
IF YOU NEED ANY BITS OF THE BRAKE LINES I SHOULD BE PICKING UP A SCRAPPER NEXT WEEK YOU CAN HAVE ANY OF THE BRAKING SYSTEM OFF THAT FOR FREE IF YOU WANT

[peester]

cool, dynamic duo

[craig green]

Thanks for the offer Dan. I have taken the pipes to my local factors & got fittings to match up. So I'm sorted on that front. I jsut need to sort T-peices & copper pipe & I'm ready to be getting on with the installation tbh.

The drivers headlamp arrived yesterday, so I fitted that last night along with the new indicator & grille. So the fr end has all new lamps now. Once the painting is done in the wheel arch I'll mount the front bumper & it ought to look like a finished car (despite not being.......).

[dan_cf40]

No probs do you know what fittings and pipe your using? sizes etc.
be useful for when i getb round to doing mine

[Adam]

No probs do you know what fittings and pipe your using? sizes etc.
be useful for when i getb round to doing mine
See my post a page or two back mate :thumb:
The solid/rigid brake line you use is 4.76mm (3/16") diameter.

[craig green]

Another flipping weekend passes with no work being done on her.

Helped my Dad working on the cottage the parents have bought (almost lost a finger from an axe wound). Spent Sunday recovering from Saturday night.

I had better crack on this week.

[craig green]

Just some recent pictures I've uploaded.

Some members are mentioning rear disc cables. Pics dont say much but show they are fitted.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build030.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build032.jpg

Cables are from Firstline products. Part nos FKB1030 (Nova long) FKB1000 (mk2 Cav short). Available at all good motor factors.

Heres the chassis leg Grant plated up for me a couple weeks ago.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build035.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build038.jpg

Just need to get a few more coats of Red on before fitting it out with metal brake lines.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build031.jpg

[Adam]

Going be done for pv?

[craig green]

Yes touch wood. Brett off MIGweb is coming round tomorrow & tackling the copper brake lines with me. 3 handed job. Seeing as the lines for the fr calipers & T piece will be mounted to the firewall, I want them done nicely, plus the tight curves under the fr arches will be tricky with just my own hands.

[Steve]

Just saw it other on mig and its looking good, not too much left to do now.

Bet it will be strange driving it after so long?!

[Adam]

Yes touch wood. Brett off MIGweb is coming round tomorrow & tackling the copper brake lines with me. 3 handed job. Seeing as the lines for the fr calipers & T piece will be mounted to the firewall, I want them done nicely, plus the tight curves under the fr arches will be tricky with just my own hands.
Cool, there pretty straight forward to do,but difficult to get them looking neat :)

[craig green]

Bet it will be strange driving it after so long?!

Oh I dunno. I drive a miserable 07 plate Fiesta TDCI which I funking hate. Cant wait tbh. Sit lower down, quicker throttle response, bit of oversteer & some induction noise from an engine with poke.

Cant wait to drive past Argos & look at my Speedlines in the window tbh. lol

[Adam]

lol

[R1CH]

Cool, there pretty straight forward to do,but difficult to get them looking neat :)

When i done mine i bent them around a (small) aerosol can, did the job !!

[Adam]

I was in a rush and pi**ed off so just bent mine by hand whilst lying on my back under the car lol lol

[craig green]

When i done mine i bent them around a (small) aerosol can, did the job !!

Yeah I'll use all manner of large sockets & jam jars for a radius.

[Paul]

craig can you get a pic of where the cable mounts to the brake and the beam please?

Sorry ot be a pain.

[craig green]

A few snaps I've taken this week.
Remember the scummy wheel arch?
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build031.jpg

Now like this....
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Redarch.jpg

The front brake lines got licked...
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Yellowpipe02.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Yellowpipe01.jpg

Looking forward to getting those on & getting some fluid in, though I'll need the long flexi to the rear before I can do that. Theres a local Rally shop (AC Services) that can make the flexi hose up for me. He's been really helpfull to me actually. Great shop & good advice. He specialises in RWD Escort stuff.[/QUOTE]

[BIGS]

Its really starting to come together now. Bet you cant wait till its done

[vaughanmc]

Red inner arches look the part - What paint did u use ?

[SRimon]

Great work craig...

Defo considering painted inner arches on mine now.

[Leeboo]

I have just read through this thread from start to finish, great project!

Makes a change seeing someone plating up rust on a detailed build, keep up the good work!:thumb:

[craig green]

Red inner arches look the part - What paint did u use ?

Red (smooth) Hammerite. About 3 tins on the wheelarches & underside.


I have just read through this thread from start to finish, great project!

Makes a change seeing someone plating up rust on a detailed build, keep up the good work!

Thanks very much, not sure if I should feel flattered or if thats a piss take. LOL. Somehow though this car is too good to scrap but not worthy of new panels & the associated labour & costs. If plated well & neatly its good enough to thrash about in IMO.

[vaughanmc]

Cheers mate I'll look some of that red paint out when I get some spare cash :)

[craig green]

HALFORDS is NOT the place to buy it, if your money is hard earned!

Mine is from Wilko.

[Martin]

HALFORDS is NOT the place to buy it, if your money is hard earned!

Mine is from Wilko.

Tell me about it.. halford sell the LIGHTEST shade of flame red ive ever seen.. may aswell paint it pink lol

there white primer is **** to.. realy waterer lol thats why ive decided to leave it and save for a respray

keep it up dude:thumb:

[craig green]

I have found there flame Red spray is rather pale, suffice to say I tried some other stuff since. I hate using aerosols though tbh.

Short progress last night though, put the fr struts back on & attempted to drop in the drivers side shaft & put on the fr caliper etc for the last time. The outer CV joint is the wrong type.... I bought all 4 new ones about 6 months ago. So not looking forward to the grovelling at the motor factors.

So called it a night.

[craig green]

Suffice to say they wouldnt take it back despite supplying odd CV joints. I had to buy another at a slightly discounted price.

So there is a brand new 22 spline outer CV joint for sale.........

[lukeo_1]

did your V6 calipers fit straight on or do you need some adapters??

luke

[craig green]

Bolt straight onto std hubs. The discs are re-drilled to 4 stud with alloy spigott rings to centre the discs (from Chris Astley). You can use FIAT 20v coupe discs if not confident in re-drilling the 288 Vectra ones.

Minimal progress this week! :(

[edit] managed to mount the fr bumper this afternoon.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/campics.jpg

Oddly, car looks quite clean despite being filthy.

[Adam]

Its getting there, looking like a car again :)

[alan b]

looks good craig, nice to see all the even gaps up front. gaps on novas are so ****e! lol top job !

[tom_beverley]

Keep it up Craig, getting there! :thumb:

[craig green]

Thanks chaps. re the front end.... Aye; considering she's filthy, grille isnt clipped in & headlamps could be levelled & fettled.


Bank Holiday Progress; PAS pipes now run through the bulkhead, brake T-pieces are drilled & mounted. Fr brake lines run out to either caliper & flexis all bolted/clipped in.

Both fr driveshafts are finally fitted into place, all bolts on fr end are torqued up (TCA's, tie bars, strut bolts etc) just leaves the hub nuts to be torqued & split pinned. (need socket)

Had a go at setting the gear linkage yesterday, but I cant seem to get it quite right. Will resort to the drill bit method through the turret I think. Never had to do it like that before.

Just waiting to get paid on 26th & will buy a battery, get the terminals crimped onto battery cables, make up some earths & buy some fuel...... main thing missing from the engine is the alternator adjuster.

[Mike]

Super progress Craig :D sounds like your not far off its maiden voyage!

[craig green]

Voyage would entail it to be taxed & legal etc......

No idea when that will be but starting her off the manifold & aiming it towards all the cocks in my neighbourhood with bike cans on Fiesta's & clifford bleepers will be fun!

Then its MOT & blag parents for a loan to get her roadworthy.....

[philly]

looking good mate, been following this project for a while its uber smart! well done

[Ash]

I want a red one again :( lol

Looking good CG, if your passing I got the right socket here I could lend you, as for the gear linkage, when I fitted my R/J'd one I just had someone hold the stick in the middle whilst the 'box was in nuteral and clamped it up, worked fine first time...

[Leeboo]

Thanks very much, not sure if I should feel flattered or if thats a piss take. LOL. Somehow though this car is too good to scrap but not worthy of new panels & the associated labour & costs. If plated well & neatly its good enough to thrash about in IMO.

Sorry only seen this now, my comment wasn't meant as a piss take lol

Yea mine has had some welding around the front chassis legs to inner wings join, in engine bay and wheelarches, and also some around the back arches and and spring seats. A good job should be fine as you say. I 'd still call mine 'solid' and 'clean'.

[Adam]

Ive never had a problem just holding the stick in neutral, with the box in neutral either Ash, never failed me.

Looking forward to seeing it running Craig, its been a long time coming :), Lol.

[craig green]

It has been a long time coming, saving on my measely budget for the parts I want & labouring on it as & when I can be bothered.

The neutral stick & box alignment is what I was trying to do using mole grips for fine tweaking underneath whilst tightening the clamp bolt. Its the rubber stick gaiter & the Corsa leather gaitor over it that is giving the stick a mind of its own & not centralising properly I reckon.

I'll get the wife to help me next time.....

[Welsh Dan]

Last time I did it, I put the box and stick in 5th, duck taped the stick into position, then tightened up, worked a treat.

[Mike]

It has been a long time coming, saving on my measely budget for the parts I want & labouring on it as & when I can be bothered.

I know the feeling Craig :thumb:

[craig green]

Couple little odds & sods this week have been wire wheeling the bunch of brake line clips I got from the scrapyard.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/campics005.jpg

I just wired them up & zinc primered them.

I have also bored a hole in the firewall & run the power steering pipes through the bulkhead & to the pump. The return line uses the existing battery/starter wire hole & grommet (cut out)

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/campics003.jpg

The front brake pipes are in & tightened up at both ends & the flexi's at the calipers.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/campics004.jpg

sorry for the cam phone pics. (Life's Good)

[Adam]

Cool.

Is the Corsa MC etc in place yet?

[Nick]

Looking good :)

I've allways had problems with my linkage with the Neutral-Neutral setup, it's allways a pain in the **** to get 5th sorted - But that's probably my linkage !

[craig green]

Cool.

Is the Corsa MC etc in place yet?

Oh yeah. has been for well over a year now. :)

[McFall1984]

looks well

[krobinson]

Finished yet ?:P

[craig green]

LOL. It ought to be.

Wanted to go out to the garage tonight, but really cannot be bothered. Dunno why.

[SRimon]

Ahhh you need some motivation :)

If mines finished before yours I won't be impressed Craig :P:P

[craig green]

I'll expect it to be tbh. The thing thats taken most of my efforts is cleaning all the grime off the underneath of the bastid. Something yours doesnt have I expect?

Hoping to complete for the SW camping trip though.

[craig green]

Currently preparing the car to be towed out for the exhaust work. Hubs are tightened & torqued. Just need to check all the other bolts & track rod ends etc. Dont want anything falling off now.

Hopefully I'll have the brakes sorted (bled & sorted totally) by next week.

[Steve]

Cool, will be another step closer once the exhaust is done. Are you having it modified or custom built?

[craig green]

My current system was custom made for another small block 16v Nova, mine has a BTB manifold but the front pipe doesnt line up with the manifold flange & it needs the BTB flange welding on. Not much work really but needs a mandrel bender to do the pipe alterations obviously. Luckily vw tuner TSR are local to me & have a mandrel machine. No other exhaust manufacturers near me within 30 miles.

[Adam]

Get some pics when its out the garage :)

[craig green]

LOL. Will do.

Bit more tinkering last night, followed by a full on tidy up in the garage.
Had to lengthen the AFM wiring, so soldering iron was out for that, cut a hole in firewall & routed the servo vacuum pipe work through, and investigated the clutch pedal spring issue I was having & got the pedal to sit lower (chuffed with that one).

I got the Mrs to help me with setting up the gear linkage again. She held the stick & I used the drill bit method as per Haynes manual, spot on result first time.

[Riggy]

as i always do it that way , and always works first time , camt belive so many people still guess lol

good news on the progress aswell

[craig green]

I've always managed to do it without the drill bit in the past tbh.

[BIGS]

glad to here your getting abit closer to having it all done, you have to get it done for the cornwall trip

[craig green]

Slowly but surely, small jobs are getting done.

I lowered it down off the axle stands once again & saw her sat on the new fr springs. (pics to come) Fairly low, may settle some more hopefully. I pushed the fr end out of the garage door way & set about drilling the hole through the bulkhead for the passenger side mounted bonnet release. All fitted & operational. (pics to follow)

Head unit is fitted & wired in with some RCA cables run to the rear should I wish to fit an amplifier.

Jobs for this week are earth cables at the various usual points, fit battery terminals etc to main power wire. See how much of rear brake pipes can be fitted which includes a lengthy run of braided aeroquip for the M/C to bias valve run.

[craig green]

've been blagged for some pics but what I've taken isnt much use tbh.

Quick shot of it poking its nose out into the sun.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build048.jpg


Pic showing L/hand mounted bonnet release cable.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build047.jpg


And the boot area cleared & hoovered of debris & awaiting my braided brake lines which will be here tomorrow.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build052.jpg


Plus whilst a bit bored on Friday evening, I took a pic with the stainless back box propped up under the car. Next major job is getting the zorst tweaked to line up with the manifold, hence brakes for towing.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build054.jpg


Hopefully more to report later in the week.

[dave955]

very nice mate

[craig green]

Thanks. Its been a long time coming. I'm like a claustrphobic mechanic, working in my single garage.

[Adam]

Getting there, getting there :)

Liking the zaust

[Nick J]

Nice to see its getting there Craig! :thumb:

[Riggy]

looks lovely craig :thumb:

[BIGS]

very nice indeed! and in the boot is that a battery box?

[vaughanmc]

Looks minted Craig

Should be good to see it done :)

[SRimon]

Yay speedlines looking good!

[peester]

cool pics, looking good

[scott.parker]

Yeah whats with the battery box mate? you running one in there?

All looks to be getting there though mate.

Scott

[SRimon]

Yeah whats with the battery box mate? you running one in there?

All looks to be getting there though mate.

Scott

Corsa Servo IIRC

[scott.parker]

Corsa Servo IIRC

Ahh lol Makes sense! :roll:

[craig green]

Cheers all. Just niggly odds & ends to sort now.

Hopefully running by sometime next week.

[Jeff16v]

Looking good craig, you missed a bit under the washer bottlelol .

[Mike]

Lend me some of your enthusiasm Craig lol

[craig green]

Looking good craig, you missed a bit under the washer bottlelol .

Thats where the washer bottle was... battery was meant to go there but it was too close to the dispack & strut brace, so will have to tack the washer bracket back in I expect.


Lend me some of your enthusiasm Craig lol

Where do I send it? Paypal? :cool:

[Mike B GTE]

looking good mate!! i love your exhaust!! the front end looks well mint.

keep it up:thumb:

[craig green]

Thanks Mike. Love your Avatar.

Heres the beauties I collected this morning, will be racing home to fit them like a school kid on his birthday!

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/braided02.jpg

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/braided01.jpg

Full front/Master cyl to rear braided lines.

[Jeff16v]

Thats where the washer bottle was... battery was meant to go there but it was too close to the dispack & strut brace, so will have to tack the washer bracket back in I expect.

That explains it:thumb:

Those braided lines are yummy, expensive?

[craig green]

The braided brake lines werent too expensive actually. I had them made up by 'exact'. Think the guy used to work for Goodridge down here in Exeter.

My local rally supplier ordered them in. Full set of flexi's for the beam & calipers was £39. Just paid £40 for these 2. One is 3 metres long & the other 75cm. Not bad IMO.

Heres the progress of starting to fit them up.

Master cylinder end.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/dscn2356.jpg

P-clipped down to boot floor, though its covered over.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/DSCN2358.jpg

From a T-piece, copper brake pipe runs out to the flexi's under the boot floor.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/dscn2357.jpg

Tonights plans are to screw more P-clips in & tuck the bias valve away on the A-pillar. (camera ran out of memory for the valve)

[Adam]

Im liking the lines :)

[Ash]

good work CG, kinda like the stealth performance thing going on - Hidden internal brake lines, etc. Very tidy ;)

[trackdaynova]

i would have thought you'd put a gromit in the engine bay where the braided line passes through...

[craig green]

good work CG, kinda like the stealth performance thing going on - Hidden internal brake lines, etc. Very tidy ;)

Cheers, that is kinda what I've always wanted to achieve. Even back when the turbo was running, no external signs of what lies within.



i would have thought you'd put a gromit in the engine bay where the braided line passes through...

I meant to have something on there, but my box of assorted grommets failed me. I will address it. Maybe find the OE one in the shed one day. There are a couple wires to run through that hole aswell, so will seal it up when I'm finished on the PAS wiring.

[craig green]

I just bought myself a pipe flaring tool for the brake lines..... report with pics & mucho swearing tomorrow.

[Benn]

Dont i have to re do mine soon.

[Adam]

Which tool have you bought Craig?

[craig green]

I got a Silverline flaring kit from Tool station. £10.18 with lifetime guarantee.

1st attempt at a flare was successfull & I proceeded to install 1 line before being bored & calling it a night.

[craig green]

Motivation has fallen away again. damn!

[Martin]

get crackin' craig.. will be soon done..

[xxspudxx]

get it done cg.....or if still cant be botherd can come out mine and help me tidy all my wiring up, is a right mess :(

[craig green]

LOL. I'm no wiring man Spud.

Hopefully get out in the garage after tea, unless the GF has other ideas.

[Adam]

FFS Craig, crack on with it :p lol

PV's like 4weeks away!

[Martin]

c'mon even i have doen some mincing today lol

[Jack]

I might even have mine on the road before you :D

[ck]

looking good craig, you not had the engine running yet? i remember that engine, allways loved the sound of it!!! be good to see it running again:D (its chris btw (tomk off mig)

how did you get on with the wiring that we were talking about over on mig? not long no wby the looks of things:D

btw i own a nova sport now:)

chris

[Martin]

PV's like 4weeks away!

oh dear

[craig green]

looking good craig, you not had the engine running yet? i remember that engine, allways loved the sound of it!!! be good to see it running again:D (its chris btw (tomk off mig)

how did you get on with the wiring that we were talking about over on mig? not long no wby the looks of things:D

btw i own a nova sport now:)

chris

Hey Chris, good to see you over here.

I'm just getting her ready to tow out for the exhaust to be done. I dont fancy firing it up off the manifold (if you knew my neighbourhood), in which case its only days away.

I have kinda sorted the wiring for the speed sender, just need to pluck a switched live from the loom for the sensor & the PAS relay still.

Minor jobs left now really. Fill & bleed brakes (for towing), connect PAS pipes, buy a reservoir & fill that with fluid.

Few bulbs & minor jobs etc. Then book it for an MOT.

I can't wait to hear the engine aswell. I keep hearing something out the office window at work, I keep missing it but my imagination tells me its a valver Nova. Sounds ace, want mine to sound similar. lol

Last nights progress involved finishing all the brake lines, got to the last one, made the pipe to length, did the last flare...... forget to put the union on first! :roll: Tvvat!

[ck]

sounds good mate, you'll have to do a little video of the first start:D i think you'll like how it sounds with the cams, sounds awesome at idle:D

remember this :D

http://i70.photobucket.com/albums/i95/ckallis500/Rolling%20Road/sm_rr_printout.jpg
http://i70.photobucket.com/albums/i95/ckallis500/My%20Car%20M174/corsaengine2.jpg

[craig green]

That engine bay pic is my phones screen saver again......

Whats the best source for a switched live? Need 1 in the battery tray area for PAS & the speed sender which come in through the passenger footwell (old servo hole)

[ck]

in passenger footwell area you shoudl be able to steal one from your original ecu's power feeds... also if you dont want logn wires everywhere for the P/S im sure there is a switched live on the wiper motor, perfectly good to use as its only going to draw a small current as its only gotto to switch the relay on.

i got another couple pics i think lol..

oh and i will dig out the paperwork at some point for the engine n that sure it will be handy for you...

chris

[craig green]

Cheers mate. Thats a help.

Wasnt that power run (pictured) done with a slipping clutch. Was it ever replaced?

[ck]

hmm, good point there. i put a good clutch in it not long before the engine was removed. they reckoned it was slipping a bit on the RR but didnt defiantly never slipped on the road..

[Adam]

What cams are fitted in that engine?

Id go straight to the fusebox for a ign live, in the battery tray.

[craig green]

Schrick apparently.

What does a switched live look like from the fuse box?

Was well pi**ed orf last night, bought overpriced brake fluid on way home, got in..... Its my Mums birthday BBQ says the mrs.. FFS! So spent all evening wishing I was finishing & bleeding my brakes!

[Lee]

If you look behind the fusebox, youll see some black wires which feed into it, which are then split across 2 fuses on one side, and then seperate wires will come from the other side of the fuses. Take the feed from the side where theres one cable and the splitter (you'll see what I mean when you look at it)

[craig green]

Think I understand....

[ck]

as confirmed by JRE (john reed engines) they are schrick fast road cams think it was 256 degree... basicly the same spec my piper fast road cams were on my old small block xe...

[Adam]

Make sure the wire you cut into is up to the job, current wise.

[ck]

i'm pretty sure its only to switch a relay so its not going to draw bugger all tbh...

[craig green]

Make sure the wire you cut into is up to the job, current wise.

About to do it shortly. Hacked a few feet of loom from a Vectra in a scrapyard this morning, to donate wiring. Got some conduit from a few cars aswell to tidy the eng bay with.

Bought all oils & filters, PAS fluids, wipoers & what not earlier. Got a PAS reservoir from the scrappy but thought it was too big... And it was. Waste of a few quid! (grr) So had to go & get a brake reservoir from the rallying shop. Lots lower so will fit under the bonnet.

Hoping to get lots done this weekend... we'll see.

[Adam]

Cool, crack on :)

[craig green]

Yeah... What I'm I doing on here? (quick catch up at a mates)

borrowing his Eezi-Bleed kit though.

[Adam]

Lol

Good move on the eezi-bleed, there cool as f**k

Make sure the cap onto the MC reservoir is a air tight seal BEFORE putting any fluid into the eezi-bleed bottle. :)
Speaking from experience lol

[craig green]

Yeah I've used them before. Eye protection is a good idea too. (from experience)

[Adam]

lol

[craig green]

Just had a mare with some soldering. Dont understand what Lee was on about with the fuse box either. Mate is gonna show me.

Not in the mood for this!

[Adam]

Lee means one supply comes into the fusebox, which then splits.
Those then go to one side of the fuse and the supply to the car then comes out the other side of the fuse.

Take a supply from the wire coming FROM the fuse, so the fuse protects the circuit.

[craig green]

All done no worries. Got a mate to point me in the right direction. Was one of them things where I knew (when looking) but didnt trust my judgement & just wanted someone to show me.


Anyway, PAS is wired in, Speed sender is wired in (just needs an earth), headlamps have bulbs & are plugged in. Brakes are semi-bled. Pedal feels pretty crap, so will do them again when I can get the car out of the garage & on axle stands again. I just need a +ve battery terminal & some ring terminals to connect up the starter wire & main loom to the main battery live.



She sits on all 4 Alessio's now & looks fab, if very dusty.

Still lots of mimor fiddly, sh*t jobs to do.......... the ones I've been putting off for 2 years!

[Riggy]

sounds like good progress craig :thumb:

[craig green]

Yeah it was. I've got a few bits to pick up at lunchtime. Then hoefully the power wiring will be complete tonight & I might go over the electrical system tonight. connect the battery, deafen myself with the alarm siren, check the lights etc.

The alternator tensioner is doing my head in currently. When (if) the engine fires up, thats still something which is gonna stop play.
Which reminds me, a can of petrol needs to be purchased soon.

[craig green]

The alternator tensioner is doing my head in currently. When (if) the engine fires up, thats still something which is gonna stop play.


Well I've just got hold of a fairly long steel alt adjuster, which coupled with the Nova GTE one I have, which is entirely unsuitable, some cutting & welding & I may be in business.

Happy Bunny for now.... :D

[Adam]

Good stuff :)

I made my tensioner from a astra spi one, basically a curved plate with a slot in it

[ck]

hmm, could have used all the original setup like said when u bought the engine.. were doing it this was on bigs saloon with the original wide belt, ill get him to post a pic of the tensioner that would have been needed..

[~~joycey~~]

:thumb: quality :thumb:

[craig green]

I didnt want the wide belt. no reason though.

This tension arm is from a Ford (gasp) so they are good for something!
I offered it up earlier & its spot on, assuming it'll be OK with a shorter belt than what I have.

I'm just at my parents place grinding a bit off it as it fouls the top of the alternator a little.

[ck]

any progress?

[craig green]

Yes & no mate.

Got many loose ends sorted, alternator tensioner, inlet all sealed down, hose cut shorter to fit in filter, battery power wires etc. 2 cans of fuel in the tank. Tried to start. No fuel, no spark. So the fun begins trying to trace why it wont go.

Lots of pics to upload.

[ck]

cool cool, hopefully have it running soon. if i were closer or even if i had a car running id come drive up.. im tempted to chuck my sport engine in my other nova for a few weeks...

[craig green]

Quick update as I've had a chance to upload a few pics. Not that happy with things however as its not been a good weekend for 'progress'.

Heres the alternator bracket I got from a breakers. It needed lots of grinding down as although it fitted well, it caught the top of the alternator & I couldnt slide it very far. After lots of trips to my dads to use grinder & vice...
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/WIPmay2008003.jpg

Then when I went to place the inlet box on....... The TB & ICV were resting ontop the end of the tension arm. B*llox! So more grinding in the vice followed by a large tap with a large hammer....
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/WIPmay2008013.jpg
(see evidence of persuasion)

New Vauxhall oil filter screwed on & filled with oil..
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/WIPmay2008005.jpg

Mantzel powerbox bolted down with inlet pipe (proud purchase) & Huuuuge K&N. Try getting a filter with an 80mm neck!
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/WIPmay2008034.jpg

[craig green]

I also got the rear quarter cards down from the garage roof. (not too dusty then!)
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/WIPmay2008006.jpg

Went on to fit them.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/WIPmay2008007.jpg


Progressing onto Sunday. I sneakily wanted to try & make the bugger run, hence me bolting on the inlet etc, plugging it all in & filling with oil. So after something I read last week, I figured I'd install some new spark plugs, ity'll need them anyway.....

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/WIPmay2008011.jpg
Then that happened & I couldnt get the plug out.... This was testing me.

After some determination & WD-40, she came out as did all the other 3 stubborn sods!

Then after fitting the new set of NGK's.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/WIPmay2008035.jpg

I filled the coolant system with anti-freeze & water.... Only to find it all pishing out into both front footwells. NOT HAPPY!

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/WIPmay2008036.jpg

[Adam]

Engine bay is looking very well indeed.

[big gra]

what a buggar. i know what its like trying to get things ready o start the engine for the first time, and things just keep happening to stop it.

youl get there eventually. looks nice

[craig green]

Cheers guys. Adam the bay is filtthy with dust believe it or not!

[Adam]

Filthy?
looks shiny as foook from where im sitting lol

[peester]

replied on mig.. keep it up dude, need to see this.

[SRimon]

Nice work Craig!

Gonna make the CAMP?

[craig green]

I'M A HAPPY BOY!

Got the engine running last night. Major thanks to Chris (ck) & Adam who clearly know what they are on about when it comes to ECU wiring, though it would appear my wiring was not at fault so I can be happy about that.

Off to get the exhaust system fitted up tomorrow, tow the car to TSR performance (VAG tuner local to me). After that its a case of tidying up some loose ends, sticking on any bits of trim that havent been refitted & investigating why this brand new heater matrix doesnt hold coolant....

MOT it & tax it for the start of June.

Simon, I certainly wont be bringing the GSi camping as it means taxing it for the last weekend of the calendar month, a blatant waste of money!

[vaughanmc]

Good progress mate - Hopefully see it at PVS then :) ?

[craig green]

Yeah touch wood, all being well.

The car seems to be throwing everything at me it can at the moment to not make it.

[The Simps]

glad to hear its running chap!

what happened to the agjustable, threaded alternator adjuster?

[Paul]

Good work! Whats up with the water leak, sorted it yet Craig?

[BIGS]

glad to see the progress this/you have made in the last few months looking great bud. bet your feeling so much better knowing it will be at pvs for the first time in years !

[ck]

wahooo lol. glad to hear u got it running mate, bet its a big weight off your back.. do the tax last lol, get her finished and mot'd. then the first day of june tax it and your done lol. :D cant wait to see it at pv :) sod it im putting my sport engine in my nova and bringin that to pv lol

[Andy_L]

Keep at it Craig :thumb:

[craig green]

glad to hear its running chap!

what happened to the agjustable, threaded alternator adjuster?

More hassle than it was worth or rather, couldnt afford the cost of custom machining something, so have put it on the back burner for now. I was probably trying to use rosejoints for the sake of it tbh. lol

Thanks for the encouragement everyone. Have really needed it at times. :cry:
I'll be chuffed this time tomorrow when it purrs through a full length exhaust. :D

[kevw]

Good progress Craig, I'm looking forward to PV, there's gonna be loads of freshly completed projects!

[craig green]

This is more stale than fresh. The car is jinxed where PV is concerened so I'm not outta the woods yet!

[Adam]

Awesome stuff.
Im pleased you got it going, as you always get your motivation back when the engine kicks into life :D

WHat was the prob then? Those cut wires?

[craig green]

WHat was the prob then? Those cut wires?

Appears so. Its odd though, because it wouldnt fire when I simply reconnected them & turned it over (even held the key in for probably 6 or more seconds..) Wired in the temporary EML like you said, the light stayed on for what seemed like ages (didnt go out) but I tried it anyway & it fired 1st turn of key really easily. I removed the EML & tried it again & it fired & I let it run for 5 seconds or so before I felt it was too loud & killed it. lol

[craig green]

Quick update.

Exhaust place had a power cut all day yesterday. I dropped it off at 10am & they'd not got any power back at 5pm when I phoned.

No rush as long as its done for today hopefully. Suffered some horrible scrubbing at the rear towing it across town, aswell as a hand brake thats over heating & burnt the paint off the disc.

Anyone any ideas on that? Drum was ringing/humming.

[BIGS]

well as soon as you get it back post a vid of you starting it, me and ck want to see your reaction to the engine :)

[craig green]

OK. My reaction the other night was. (jump)!!!!!

Was bricking it off the manifold in my single garage. LOL