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craig green
18-08-06, 06:53 PM
This is the WIP thread for my Nova GSi. Ive owned it since Sept 99 when I bought it as a completely std H reg GSi in flame Red. I am a bit of a purist when it comes to Nova's, so although I planned to modify it heavily I always wanted it to look like a Vauxhall product & not fall into the trap of sticking all manner of boy racer hardware on it.
Sadly I have no pics of it as I bought it. It was on std 3 spoke GSi wheels, std ride height & had the hagglers bonus of shot fr brake pads, bold fr tyres & an almost vacant clutch.
Within weeks of owning it I had replaced the clutch, had the bolster wear on the fr seat repaired & generally serviced all round incl new GM freedom battery, water pump, tensioner & cambelt + 2 new tyres on the 14" 3 spokes.
I always knew in the back of my mind I wanted have the original 1600 powerplant turbo charged. 3 reasons. 1 was to keep the originality of the factory engine numbers etc. 2 was because I didnt want to join the usual list of people using the easy route of an XE or LET to make there Nova quick. 3It is well documented that a big twin cam lump has a negative effect on the handling characteristics of the Nova, tbh it is this attribute that makes a Nova such an enjoyable experience for me. To detract from that would be madness in my eyes.
So a 1600 8v turbo it was to be. After 2 years of gentle modding of the std car. 15" team Dynamics Monza's, GSi 16v calipers, Bilstein streetline suspension (crap btw), SEAT ibiza splitter, Powerflow custom S/S exhaust & K&N panel filter. The engine was removed for a full rebuild incl new pistons aswell as a Courtenay cam & CS15 big valve head. The 1000th running in mile passed whilst enroute to Courtenay in Norfolk (some 5hrs from my neck of the woods). 2 weeks later I returned to North Walsham & had the joy of driving home with over 60% more torque & a fluttering wastegate.
Here just days after returning from Courtenay Sport....
http://i30.photobucket.com/albums/c323/turbocraig/RustyNovaPics/2ndpics005.jpg
8valve turbo engine bay...
http://i30.photobucket.com/albums/c323/turbocraig/Craigypics/CraigNova2.jpg
That was 2001, the engine has been sold on due to issues with fuel injectors & bigger plans. The car also saw an almost bare shell rebuild in 02 wher it had a new passenger door, custom vented bonnet & new fr panel. The mandatory 16" Speedline Alessio wheels also went on as did KONI suspension, rosejointed TCA's, polybushes etc Whilst the engine was removed, the bay was strengthened with the Harry Hockley Grp A chassis plating kit & the bay was sprayed flame Red.
Over the years in my ownership the rear end of the car always likes to surprise me with rust issues come MOT time which currently brings me to the latest rebuild. The rear chassis legs are so shot that I took the car off the road in Dec 03 & have only taken parts off it since.
http://i30.photobucket.com/albums/c323/turbocraig/RustyNovaPics/2ndpics003.jpg
Now my Nova fetish has bitten again.. let the rebuild commence. This time I dont care for how genuine the car is, there are far tidier GSi's than mine. It is to be built as a fast road car that I can use for track days & shows.
Prior to work starting...
http://i30.photobucket.com/albums/c323/turbocraig/Sta40006.jpg

Progress so far.. The rear turrets are going in...
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Turret_1.jpg

Heres the turret being fettled & cut ready to weld in.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Turret_3.jpg
Also we have used the original mounting lugs from the shell on the upper turret face
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Turret_2.jpg

Heres the new powerplant btw...
http://i30.photobucket.com/albums/c323/turbocraig/bits4sale/Novabits008.jpg

CG

ade
18-08-06, 06:59 PM
looking good! Know what you mean about being bitten by the nova fetish!

craig green
18-08-06, 07:02 PM
LOL. After I took it off the road I got into Cav GSi's & GTE 16v's & just generally looking after myself living at my own place. Been back on here regularly since xmas & been driving a 1.2 beatertm though & cant wait to get back behind the wheel of the old girl.

Here it is on the trailer leaving.

http://i30.photobucket.com/albums/c323/turbocraig/holiday_frpanel_gsi017.jpg

http://i30.photobucket.com/albums/c323/turbocraig/holiday_frpanel_gsi019-1.jpg

Ste L
18-08-06, 07:15 PM
looks like its going to be a good project, its going to be a stipped out track/drag beast or a full car, i.e interior etc etc

Adam
18-08-06, 07:19 PM
Nice one, should be cool when finished :)

Nath
18-08-06, 07:30 PM
just out of curiosity how much did courtney charge for a turbo conversion?

Ste L
18-08-06, 07:44 PM
im sure its like 2 or 3k for turboing the 1.6 8v

Nath
18-08-06, 07:54 PM
maybe ill give it a miss then lol. but great car mate, keep us all updated!!

craig green
18-08-06, 07:57 PM
The car will likely be semi stripped. I'm not going to totally ruin it by chiselling off the seat mounts etc straight away. As it is the new rear turrets wont be in the way of the rear seat mounts, so it could have the rear seats in although I was expecting to lose them tbh. Ive got no immediate plans for buckets either so I will say its gonna have a full interior for now.

I paid ?3k for the basic Courtenay job. I had a cam & cyl head too aswell as some springs so I think I spent ?4k :eek:

Lee
18-08-06, 07:58 PM
3It is well documented that a big twin cam lump has a negative effect on the handling characteristics of the Nova, tbh it is this attribute that makes a Nova such an enjoyable experience for me. To detract from that would be madness in my eyes.

tut tut, has me and dar taught you nothing lol

Looks like a cracking build mate! :thumb:

craig green
18-08-06, 08:04 PM
tut tut, has me and dar taught you nothing lol

Looks like a cracking build mate! :thumb:

I'm waiting for the abuse after writing that tbh.... But NO, I havent learnt yet. Maybe when the 16 blows I'll XE it (pigs might fly) lol

novacabrio
18-08-06, 08:19 PM
Nova (Corsa A) 1.6i 8v150 bhp?3195

Not much of a increase over the years bet most of that price is in labour

martweaver
18-08-06, 08:30 PM
All good mate!! glad to see its going to make a comeback. :thumb:
You will sort that rust out no problem, I sure Keith had a rear chassis leg kicking around!

Mart

PS - you missed a cracking curry at Billing :D

Ash
19-08-06, 02:10 AM
Now my Nova fetish has bitten again.. let the rebuild commence.

CG

Great! I'll have this to look forward to then lol

Really like the thinking behind your nova, looks like a really good rebuild,
what engine is that btw? C16XE? what inlet will you be running? turbo? ITB?

Keep up the good work

Ash

luke langton
19-08-06, 10:56 AM
Nice too see you have been bitten by the nova bug again! Sounds like some good plans can?t wait to see it done, is the engine going to be N/A or turbo?

craig green
19-08-06, 01:01 PM
Engine is N/A for now but hoping to have it forced induction after the winter perhaps. Just need to get it on the road & drive it tbh. Hasnt spun a wheel since Dec 03 IIRC.

Adam Moran
19-08-06, 03:51 PM
Hi Craig,

Looking good :)

I'll take you out in my car when shes back and that will be enough for you to change your mind.... trust me.. im a doctor (well almost ;))

craig green
20-08-06, 04:18 PM
Cheers Adz. Any rides in a sweeet Nova duly appreciated. No need to convert me... I just do my own thing.



Only dead fish follow the stream.

Have spent the morning cleaning up the power steering rack & putting a coat of primer on the gearbox prior to the top coat of anthracite gloss.

Ordered new exhaust mating/sprung bolts yesterday, new fuel hoses & rear beam bushes.

craig green
23-08-06, 12:52 PM
One side of the rear turreting is finished (structurally)

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Turret_7.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Turret_6.jpg
Undersealed.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Turret_8.jpg

Looking forward to the otherside being completed & moving onto the r/disc conversion. Drums just dont feature on performance cars IMO.

dhdev (Oli)
23-08-06, 01:00 PM
Nowt wrong with drums ;)
Loving the car craig, will definately keep an eye on the progress :thumb:

craig green
23-08-06, 01:04 PM
Cheers Oli.

All comments welcome.

BigStan
23-08-06, 01:10 PM
Keep up the good work mate !

coochiSR
23-08-06, 03:30 PM
very nice mate, can't wait to see the finished product, lots of moeny being spent too, should look the nuts, will stayed tuned for the rets of the project. keep up the good work!

Coochi

stuartp
23-08-06, 05:56 PM
Some good work going on there!! I see there is extra plates on the inner arch is that for extra support or TIM WORM?;)

craig green
26-08-06, 06:55 PM
Plating is for tin worm. Damn!

craig green
16-09-06, 08:07 PM
Been cleaning out the back end ready for some seam sealer this afternoon.

Heres a few pics of the turrets as they are & some of the parts I will be fitting.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build005.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build004.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build007.jpg

The other side
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build006.jpg

From outside
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build008.jpg

Heres the Corsa hydraulic PAS rack. 2.5 turns lock to lock. (is that kwik)?
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build001.jpg

With the 12v pump from Power steering services
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build009.jpg

Painted V6 Vectra calipers, 16v rear calipers & new 288mm GM discs
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/GSi_build002.jpg

Currently got the Corsa GSi servo & pedal apart for cleaning & colour coding. (pics next week).

Adam
16-09-06, 08:27 PM
Fook, looks like you've had to plate quite a bit,Lol.

Good work tho, the rear turrets look top notch :)

bump
16-09-06, 08:31 PM
The tin worm had bitten pretty bad!

craig green
17-09-06, 08:16 PM
Yeah it was under the boot floor that was worst. To be fair though it doesnt make sense to put in multiple small patches when a large one would look less patchy & make it easier.

Dash out today & tackling the new servo positioning.

Matt2107
18-09-06, 10:31 AM
Nice one craig.... the turrets look excellent.

craig green
09-10-06, 01:12 PM
Fuel tank has been refinished over the weekend. Underside is Silver & the upper will be black. This is to contrast with the suspension & beam etc.
Also the brake transfer bar & the new Corsa servo should be in (place & mounted) by tonight.

Tank being degreased.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/tankservo001.jpg

Tank being painted. (this end had some corrosion)
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/tankservo010.jpg

Painted, other side to be done black.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/tankservo009.jpg

Ive got new rubber tank hoses coming from Vauxhall & a new Walbro fuel pump too.

Oh forgot to mention. my Corsa GSi track rods should be here for the PAS rack to go on aswell. May have the engine in at the weekend if the servo placement & steering rack go on as planned. Rack will need the hole in the bulkhead enlarging & the Corsa track rods will need to be shortened in order to be the same 'track' as the existing set up.

The Simps
09-10-06, 01:30 PM
Only just spotted this thread Craig. Ace work on the turret. Probably the best I've seen done so far. There's something very factory about them.

Reading your words on this thread and others I think we share very similar tastes when it comes to our cars.

Keep up the progress updates.

Simps.

craig green
09-10-06, 01:38 PM
Thanks mate. Means a lot coming from a connoisseur such as yourself. LOL

Thread on MIG too.

The Simps
09-10-06, 02:32 PM
Thanks mate. Means a lot coming from a connoisseur such as yourself. LOL

Thread on MIG too.


I take it you're reffering to my extensive and varied porn collection? :thumb:

Simps.
lol

Matt2107
09-10-06, 02:44 PM
Its always nice to do a proper job :D

Well done mate.

craig green
09-10-06, 02:50 PM
I take it you're reffering to my extensive and varied porn collection? :thumb:

Simps.
lol

NO. But now you mention it, yeah..its all good. lol

Thanks Matt.

The Simps
09-10-06, 02:58 PM
Seriously tho. I think the hardest thing about building a car these days is that the standard is SO high and coming up with new original ideas is becoming more and more difficult.

Simps.

Matt2107
09-10-06, 03:00 PM
Agreed... its hard to please a market thats seen pretty much everything.

Its now all about imagination.

craig green
09-10-06, 03:42 PM
Seriously tho. I think the hardest thing about building a car these days is that the standard is SO high and coming up with new original ideas is becoming more and more difficult.

Simps.

After nearly scrapping this car & not wishing to waste anymore money, I'm quite happy to accept I will never build the Nova I really want & will just get on with the functional side of things & make a car I can be proud of that boasts the little touches & mods here & there but is essentially a good usable fast road/track day car.

I no longer have the patience nor interest to be flushing out body panels & worrying over minor scratches & seeing my face in the exhaust boxes.;)

Bit of a shame, as Ive had some cracking ideas over the years but have never really executed them.

The Simps
09-10-06, 05:14 PM
I know what you mean. I'm not after concourse (sp?) or even stupid performance. All I'm after is around 250bhp of reliable power that can be smacked around a track all day without problems and a car that looks like it could have rolled off the factory line with the mods that have been done. And of course add a few little Simps touches to be different!

I think we're both on the right paths mate!

Simps.

craig green
09-10-06, 05:19 PM
Aye.
Theres nothing I'd like more than to do a crazy nut & bolt resto' but I feel like Ive come to my senses ever since I moved out of home & tbh I have almost no motivation to be spannering under my car. Those days seem to have gone, however I am having a hoot charging about the place in my 1.2 so I have no doubt I will enjoy this when I'm done building it.

Been home at lunchtime & my Corsa track rods were there courtesy of VPSC. :thumb:

Riggy
09-10-06, 05:26 PM
looking good craig , glad you kept this one as it did look mint :thumb:

krobinson
09-10-06, 06:09 PM
All looking good craig, should see this at the shows next year then :)

Lee
09-10-06, 08:22 PM
Good work matey! Keep it up, hope your finger nails are as full of crap as mine are at the mo lol

stuartp
09-10-06, 08:41 PM
hows the corsa servo coming on mate?? like simps has said mate your work on your car is excactly how i wont mine keep up the good work and keep us posted!!:thumb:

nova ian
09-10-06, 09:17 PM
Looks like a good build. Rear turrets look spot on. Good work fella.

Ian

craig green
11-10-06, 11:53 PM
Had a busy day off from work & have set about sorting the Corsa servo into its rightfull position, after much debating & research. Here goes.
Its going in the battery tray as previously written, here;
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/London_Jay-Z_Nova015.jpg
With the battery removed from the battery tray area, it looks a little something like this;
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/STA40597.jpg
Here is said Corsa GSi servo & master cylindeder assembly;
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/tankservo004.jpg
Its mounted through a stiffening tray that has extra bolt in points than just the servo-to pedal bolts (x4).
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/tankservo005.jpg
First job was to rid the inside of the footwells of the old transfer bar & pedal assembly/litter
Out with the pedals...
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/STA40581.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/STA40586.jpg
To leave an empty bulkhead...
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/STA40584.jpg
Then set to with creating the 2nd support for the clutch pedal as the Nova brake pedal was the 2nd support bracket for the std clutch pedal. To do this me & mate Rob decided to space the existing brake pedal (now chopped down in length) closer to the clutch pedal & then rotate it 180 degrees so it now sits up at the top of the bulkhead/underside of the battery tray.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/STA40600.jpg
We then welded to lengts of steel in a V formation to sit in the recess under the bulkhead by where the new support bracket could meet & be bolted down securely.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/STA40601.jpg
Here is the support bracket bolted up independant of the clutch pedal (note wing nuts used for quick installation).
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/STA40602.jpg

This was then welded up solid & relevant sized holes drilled & then sprayed with primer.

craig green
12-10-06, 09:09 AM
Moving back out to the battery tray, we had the holes centre punched so we needed to bore the large hole to pass the plunger on the servo through which mounts up to the pedal in the car.
A few score lines & marker pen marks & we got this...
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress002.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress001.jpg
Which meant we could slot this in...
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress003.jpg
Next step is to straighten the Corsa's pedal & then work out the position of the pedal pad as it will need to be shortened to bring it up inline with the clutch pedal next to it. We hacked off the bottom part & then used molegrips to adjust the position before welding it when happy with the result.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/tankservo006.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress007.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress010.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress008.jpg
That will be welded properly & painted up by tomorrow, so the next stage of swapping to the PAS rack & deciding where to put the 12v pump in will be next, as is ordering a bias valve (in-car adjustable) & making up the piping for the brake system.
Order the hoses, pipe, fluid, spigot rings, PAS plumbing & reservoir ?tc ?tc.

Ive also obviously had the steering column off, so I have been able to change the column bearing Ive been itching to do for a few years now..
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/STA40580.jpg
Its located under the upper column cowling, in the brown plastic bit in the centre, the old OE bearing was pretty ruff.
New bearing & old bearings.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/STA40578.jpg
Thenew one is slotted in with some marine grease to keep it smooth, I put some grease on the lower plastic bush that the coloumn spins on too.

dhdev (Oli)
12-10-06, 01:21 PM
looking very nice!!! :thumb:

Word of warning, the nova bulkhead/firewall is very weak. I had to create a large metal wedge construction to brace the back of the pedal hinge bracket to the bulkhead. Its hard to describe, but when i pressed the pedal hard the battery tray would flex upwards like hell and attempt to seperate at the seam with bulkhead.

stuartp
12-10-06, 07:29 PM
looking good craig!! keep us posted!! and i'l bear that in mind Oli!!

Matt2107
13-10-06, 10:51 AM
Lovely fella.

craig green
13-10-06, 08:07 PM
Thanks. Bit more progress...

PAS rack is now fitted (well hole drilled) anyway & the pipes are ordered up from PIRTEK.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress012.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress013.jpg
Got these Samco's from an SR I broke last month, should be able to use a couple of them with a bit of luck.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress011.jpg
New Walbro fuel pump arrived today aswell (thanks JoeThrelk). Nice.

just gotta sort where I want to put the battery & the PAS pump, then I can calculate the lengths needed for the pipes.

Welsh Dan
13-10-06, 08:14 PM
Put the battery in the boot :thumb:.

craig green
30-10-06, 04:46 PM
Saturday 28th Oct 06. My mate Rob came round wiv BIGG Mikes crane. This is Rob hauling the engine out the garage whilst I hold the camera & keep my hands clean. As it happens I helped lift the engine out to here & had my fingers in the muckiest place possible, really gacky oil on my hands. (Not good for the camera) LOL http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress020.jpg

Here she is sittin under the raised front end in anticipation for the car to be lowered over the lump (sorry Benn, its the best way!). Consequently we only removed the wheels & tie bars for this today, easy with an impact gun.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress021.jpg

And here sitting pretty... in quite nice time, my TAS mounts arrived from Karl Rowntree this morning, thanks bud.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress025.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress014.jpg

Here it is just hanging out in the shade..LOL
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress022.jpg

Now the engines in out the way, my Dad will quit moaning & I'll have a much better idea as for where to put the 12v PAS pump & where to route the pipes, locate the reservoir & hide the battery.
Any suggestions, mainly for the PAS graetly accepted. By the way! Does anyone know the ins & outs of a Corsa GSi PAS rack & which union is pressure &/or return?

macc nova
30-10-06, 04:59 PM
nicely done:thumb:

craig green
30-10-06, 05:00 PM
Heres my brake bias valve for the rear disc brakes..
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress026.jpg

The BRAND new Walbro fuel pump I got for ?65..!!
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress027.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress028.jpg

Should be busy this week, Ive got plenty to be getting on with.. Slap me if I'm SLACK!

Stoo
30-10-06, 05:01 PM
Hi mate, looks a great build, sorry to be a pain but could you give me abit of info on whats needed to fit Corsa PAS and also Turrting the rear

Cheers

draper
30-10-06, 05:26 PM
looks good craig, im really likeing thise rear turrets aswell

craig green
30-10-06, 05:43 PM
Hi mate, looks a great build, sorry to be a pain but could you give me abit of info on whats needed to fit Corsa PAS and also Turrting the rear

Cheers

The Corsa hydraulic PAS is using a Corsa B hydraulic rack (GSi) & then shorten the track rods 1". I will have to get custom pipes made to plumb it into the 12v electric pump Ive bought. The rack needs the hole into the cabin enlarged as the hydraulic rack is a bit bigger here.

The turrets are hard welded into the rear chassis legs & boot floor/inner wheel arches so that the coilovers can take the full weight of the rear of the car & then the inner arches wont have to be dressed with a hammer to clear the coilover bodies. (std body shells with coilovers @ the rear can pop the inner arches apart). My shell was really rusty at the chassis legs, so I chose this expensive option to do away with rear springs, which essentially means the chassis leg/spring cup isnt structural anymore.
My Dad made the turrets or you can buy off the shelf mk2 Escort (rwd) ones from rally accessory suppliers.

craig green
30-10-06, 05:48 PM
The old servo mount is quite handy for running the loom into the cabin. Grommet fits a treat too.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress025.jpg

I think I'm going to mount the battery here via a welded tray bolted to the servo bracket. Should look factory & then I wont sacrifice volts or boot space by having it in the boot, not to mention a kilo of positive cable!

krobinson
30-10-06, 09:08 PM
Looking good craig, love it :)

Keith

The Simps
31-10-06, 03:22 AM
Could the PAS tank go where the washer bottle tank goes then get a washer bottle from a scrappy and have it in the wheel arch?

Simps.

The Simps
31-10-06, 03:23 AM
p.s I do hope that engine will be coming out again to be cleaned and painted up ;)

craig green
31-10-06, 02:58 PM
p.s I do hope that engine will be coming out again to be cleaned and painted up ;)

In a word NO. been there & done that, it doesnt last & makes me want to cry when it gets dirty, the engine has a clean (20k) bottom end anyway & I will have the rocker cover polished & buffed again I expect + I will paint the g/box. Should have done it before I installed it but couldnt be harassed.

I think I will move the washer bottle into the scuttle tray & try to mount the PAS pump below the battery which should with a bit of luck all fit in the void above the gearbox/OE servo position.

pul16v
31-10-06, 07:55 PM
I think I'm going to mount the battery here via a welded tray bolted to the servo bracket. Should look factory & then I wont sacrifice volts or boot space by having it in the boot, not to mention a kilo of positive cable!

il get you a pic of my tray in that place so ya can see what it looks like

phil

craig green
31-10-06, 08:24 PM
Ah nice one! Great minds think alike.

Ash
12-11-06, 06:28 PM
Ive got plenty to be getting on with.. Slap me if I'm SLACK!

*SLAP* lol, any updates? or has it been put away for the winter? Should be able to pick that CS15 head (if you still have it) up in about a month when im back home with transport. very good project btw:thumb:


A

craig green
13-11-06, 04:01 PM
Very slack here..

Head is sold buddy. Went to a mate of mine with a 1.6 8v turbo!!

Ash
13-11-06, 04:17 PM
:cry: oh well, if only i had the cash at the time. At least its beening put to good use.

A

craig green
13-11-06, 04:49 PM
Yeah. Soz about that, needed it gone for some time & let it go to Luke, he had the cash.

craig green
10-01-07, 10:47 PM
OK. Dunno where the motivation came from but Ive just returned from the garage.
After all the rain & shizzle we've had here in Somerset recently, the hole I bored in the battery tray was letting water into the cabin & suffice to say the drivers footwell was a bit damp. So I want the servo bolted down once & for all. I had to remove the rear battery rest, which left behind a bunch of holes from the spot welds. Anyone that knows about Novas will be aware that the battery tray is above the drivers feet. Any holes here will give you damp jeans & probably a wet fuse box, FORD Orion stylee.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress031.jpg
So spot weld holes sealed up with some seam sealer..
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress033.jpg
And Ive also had some slight surface rust from where the battery has moved in the past & rubbed the paint. This has been on the car since I had it 8 yrs ago. Its never got worse or bothered me, but rust does have a habit of eating through metal & making holes, so again for the sake of dry jeans & sound electrics Ive rubbed it back & etch primed it.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress034.jpg
Tonights work in its entirety. LOL
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress036.jpg
Little tip for 2007. Judging by all the Nova builds, invest heavily in this stuff. Guaranteed return!
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress032.jpg

Tomorrow I'm going to bolt in the servo, pedal & mounting plate with the sealer ring so its water tight.
Then brake lines, something Ive been stalling on.

craig green
21-01-07, 06:08 PM
OK. Been under the fooker again this weekend. I need it to steer so I can move the car about & begin some work at the rear end (tank etc).

I had to remove the old std manual steering rack. here undoing the rack mounts from under the car (drivers arch)
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress047.jpg

With the rack off I measured accross the centres of the 'rod ends' so I could set up the PAS rack to the same width just as a reference & to make tracking it up quicker when she's a goer.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress049.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress050.jpg

getting the old rod ends off was a proper biyatch! Some WD40, bashing with a hammer & heat from a blow torch got em off though (I needed the rod end lock nuts).
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress050.jpg

Heres the Corsa B PAS rack with new rod ends on
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress055.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress054.jpg

The knuckle on the rack that enters the cabin through the bulkhead is much larger on the PAS rack, no doubt due to the hydraulics within, so the bulkhead has to have the hole enlarged (see previous post) so I had to make a grommet type seal to go around the edge of the rack & bulkhead gap.
My can of WD was about the same dia as the knuckle on the rack, so I used the can as a template to cut a hole in a peice of thick rubber I had.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress058.jpg

Heres the grommet on the rack.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress059.jpg

Heres the rack being bolted onto the car.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress064.jpg

Ive had to work alongside some of my old mans shizzle in the garage. Probably the main reason why my progress is so slow. If he isnt rebuilding old bikes of his own, he's peering over my shoulder & telling me how I ought to be doing something.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress061.jpg
Theres another 5 bikes in the way too!

Green16v
21-01-07, 10:32 PM
Good to see you on it mate

Timmy
21-01-07, 10:42 PM
Very good work will use this thread when i finly get my new car loving it load keep up the great work

Benn
21-01-07, 10:50 PM
dude more gen needed on the rack...

The Simps
22-01-07, 01:00 AM
ah u found some inspiration this weekend too! good work my friend.

Simps.

Matt2107
22-01-07, 10:14 AM
Well done Craig.

craig green
22-01-07, 04:38 PM
dude more gen needed on the rack...

Its a modded Corsa GSi rack from a rally car . Any Corsa B rack will fit a Nova. The one I have is from a Nova rally car though. The track rods have been shortened to match the novas track (width) & the internals had been swapped for 'kwik' items which now has a lock to lock of 2.2 turns, compared to 3.75 turns for a regular Nova jobber. Nice!

I was really lucky to pick up the rack off ebay about a year ago for less than ?40. Ive also got an (almost) brand new 12v Saxo pump. I got that for a pittence aswell, so I'm really chuffed with how much its cost.

All I need is the hydraulic lines making now, which I'm struggling with as my local Pirtek chap is dyslexic (putting it kindly).

BigStan
22-01-07, 06:46 PM
Good Stuff !

Jeff16v
25-01-07, 06:12 PM
Turrets look the nads, talking of which, you must have nads the size of basketballs cutting lumps that big out of its ass!lol

keep it up!

craig green
25-01-07, 06:21 PM
Aye. Was almost scrapped though so it want too big a deal.

its been far too cold to get out into the garage over the last 2 nights.

I should have a nice package arriving in a few days which I'm quite excited about receiving. More news when it does. I'm also just waiting to get the details on how to plumb the power steering in. I havent got a clue which outlets on the pump (3 of) do what? The rack has 2 ports.

Dash & column should be going back in over the weekend along with the pedal box from the Corsa.

Having some spigot rings made for the V6 discs too, cant be doing with paying for em.

Mike
25-01-07, 06:54 PM
top stuff craig! just rad thru the thread and looks/sounds like its gonna be an ace motor tbh!

Mike

craig green
26-01-07, 05:46 PM
Thanks mate.

Aswell as the personal goal, I dont mind admitting its nice to get recognition too. Most of the ideas & stuff is what Ive been wanting to do for years. Finally getting somewhere with it now, although I'm moving house in a month which might slow me down, but I will have my own garage!!

The main goal is to get it to PV or Billing this year & I rather it was PV tbh as then it'll get to both!

Benn
26-01-07, 07:44 PM
hope it will be dude,
would love to see it..

Adam
26-01-07, 08:46 PM
Nice work Craig, looking good

Matt2107
29-01-07, 11:12 AM
but I will have my own garage!!


Once you've got your own garage it'll come on in leaps and bounds.
You might have to purchase lots of flowers for your gf though ;)

s14a
30-01-07, 02:50 AM
nice work craig, keep it up

craig green
05-02-07, 04:30 PM
Once you've got your own garage it'll come on in leaps and bounds.
You might have to purchase lots of flowers for your gf though ;)

flowers...... maybe I'll start a window box as my next project!

Friday night saw some mincing straight after work, only pausing for food & I kept going until 10pm. Sall was not happy!

I made another bulkhead grommet for the cabin side of the bulkhead to seal the rack. The column has now gone back in & the pedals are mounted back in for the last time, all the pivots nicely lubed with marinee (under water) grease.

Ive also re-routed some of the wires on the loom (+ve) to aim them at the battery (when its fitted).
Next job, maybe tonight is to start putting the main dash fascia back in & hiding the immobiliser & alarm. Then set about mounting the ECU on the bulkhead, hopefully behind the glovebox.
Then I might have to look into wiring in the engine loom/ECU & that will begin the process of getting the engine running which involves making a new bracket for the fuel pump too.

Never stops does it! (pics tonight)

Lee
05-02-07, 04:33 PM
Look forward to the pics, but by the sounds of it, some top quality mincing!

ps. Mind the hazard switch lol lol

craig green
06-02-07, 12:27 PM
some pics....
The Corsa servo & its backing plate along with the pedal was bolted & sealed down finally with this gacky, rubber seal stuff. Courtesy of a mate who is a main dealer mechanic at VW, they use if for a bodge on the new Passats. NICE!
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress076.jpg
Heres the rack entering the cabin, see the rubber grommet & installed in the bay side.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress079.jpg
Heres another grommet or storm flap (LOL) for the interior so hopefully it will be nicely soundproofed from engine/road noise.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress080.jpg
The pedals & steering colums w/UJ are now finally in place.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress085.jpg
Here are the plugs & wiring for the ECU/engine in the passenger footwell.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress082.jpg
Not sure I recognise this one?
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress083.jpg
Heres the main power & feed(s) plug.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress086.jpg
I think I'll cut the similar plug from another E16SE loom & tap into the Corsa engine loom so it will simply plug straight on, makes sense IMO.
Plus I got to view a car with the same PAS setup as mine at the weekend. These pics make plenty of sense to me.....
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress096.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/work_in_progress106.jpg

KPautomotive
06-02-07, 12:40 PM
The plug you dont reconise is not used matey. Ive just taped mine out the way

craig green
07-02-07, 12:07 PM
Nice one!
Any idea what it is for reference?

craig green
02-03-07, 12:29 PM
UPDATE.
The Nova has now moved house with me. Ive got my own garage now so she is firmly in the dry & I can work un interrupted until way into the late hours (if I want).
I got a tow from my Nova TD whilst I sat & piloted the GSi to my new gaff on Saturday. Quick rack felt good!
Here she is in my garage.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Motors002.jpg
First bit of messing was emptying the shell of all the bits Ive been stacking up & storing in the car, treating it like a shed!
Been meaning to see if my PAS pump will fit alongside the brake servo in the old battery tray....
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Motors006.jpg
Affirmative!
I bought a halogen work light yesterday to help with seeing what I'm doing. need to invest in a 1/2" socket set aswell, seeing as my Dads tools are across town now! Also hope to build a workbench & get a bench vice over the weekend aswell.

Ive been looking into the ECU & engine wiring this week, thats already thrown up some issues. Seem to have some odd coloured wires. I expected that tbh. I HATE WIRING & ELECTRICS!

craig green
19-03-07, 03:52 PM
STOP PRESS
Ive made a work bench for the garage !!

Timmy
19-03-07, 11:10 PM
cg you get that plug of RJ was it the corrct one ? im still messing with moing so my GSI is waiting. once i moe it wil be full steam ahead

craig green
20-03-07, 12:02 PM
Was meant to text him at the weekend but totally lost track & got carried away cutting up wood & drilling holes & stuff. So I havent seen the plug yet.

I assume your 'V' key isnt working? Good luck with the move though kid.

Bench is sorted now, except I need to buy the material for the worktop surface, then I will be cracking on with cleaning & spraying etc, lots of parts that can be bolted on to the car.

craig green
12-04-07, 01:39 PM
Fuel lines have been sorted & new clips coming, small bit of rust been attended to on the underside (very minor), & the plug for the engine management will be soldered on probably tomorrow.

Ive been feeling seriously under the weather for the last couple days. Progress has been slow in the bat cave (garage) but I've managed to get on with a few odd jobs;
Existing fuel lines along the cars underside have been rubbed down & treated with zinc primer & a nice coat of contrasting paint.
(here as they came off)
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/movein028.jpg
(Here after being sprayed)
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/movein019.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/movein020.jpg
Obviously all the clips, fasteners & fuel hoses etc will be cleaned up & renewed where necessary. Ive got a new Walbro pump for it but will have to make up a new bracket assembly as the old one was pretty rough & I sold it.
The multiplug for the ECU to connect up the std car wiring harness is now all but finished being soldered in. Ive chosen to adapt the C16XE ECU loom to incorporate the same plug as the original E16SE engine did so it would plug straight into the car with minimal fuss & not involve cutting anything away from the cars wiring thus not looking like a bodge & making it simple if me or anyone else were ever to refit the original engine again.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/movein034.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/movein033.jpg
Thumbs upto Brett for donating some GM wire to keep the extension to some of the diagnostic & rev counter wiring inkeeping with Vauxhall colour coding..
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/movein021.jpg
The old 16v spec fr brake calipers & discs have been removed along with the last of the GM metal brake pipes & the old flexis that were no doubt original 1990 items. The hubs & knuckles etc were still pretty clean from when they were painted up in 2002;
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/movein029.jpg
And the wheel bearings are fine too... (bonus)
Theres a coat of Hammerite needing to go onto the G/box after I 2nd coated it at the weekend;
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/movein024.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/movein027.jpg
The driveshafts have been brought round to the bat cave in order for them to receive a coat of paint & be built back up with all new boots & grease (after a thorough degreasing).
Crusty shaft..
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/movein032.jpg

Off to collect the power steering pipes & setup in a minute from the Hydraulic place (Mayflower Hydraulics) TOP DUDES!

Looks like I have located a new exhaust suitable for N/A too. watch this space.

craig green
12-04-07, 01:42 PM
I went to a scrapyard yesterday too & got a battery tray & mounting brkt from a Corsa B aswell as a funky screen washer bottle (pics to follow).

I was rather inquisitive about the BTB manifold & what it lines up like under the car, so threw it on;
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/movein030.jpg

Jack
12-04-07, 02:39 PM
Good work happening here :D

Saw you walking across towards Natwest in town earlier lol

craig green
12-04-07, 05:36 PM
Must've been my lunch hour......... didnt see you.

Did see you in the Celica at some point at the weekend. Canny member where tho!

craig green
13-04-07, 02:36 PM
Power steering pipework & fittings all collected. Nicely done I must say & other than maybe one of them needing shortening by an inch, it should be fairly straightforward fitting it up.

Just getting impatient waiting for my new heater matrix, this is holding me back from installing the dash & carpets & seats etc. It might look like a real car soon.

I'll do another update after the weekend with new pics etc.

craig green
28-04-07, 12:40 PM
Well, the matrix has arrived but no rad. Cool, though. I need the matrix to start putting the dash in.

Assembled the fuel pump & its bracketry last night & painted a few bits. Just ordered my new inner CV's (might aswell) from my local factors this morning & am about to spray my cross member as it looks a bit rough from coolant leaks & once upon a time supporting an intercooler.

Hopefully I'll sort a few things over the weekend.

craig green
02-05-07, 04:43 PM
Heres the new VALEO matrix. Its now tucked away in the matrix housing & bolted upto the bulkhead.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/combeWIP070.jpg
I dunno if I had troubles bolting it back on because of the mods I've done to the pedal assembly, but I was spitting blood last night, cursing like F**K at the rear nut on the drivers side of the matrix housing. Cant see it, no access with the socket & extension bar. (In now anyway)
I sliced a section out of the rear bolt hole which allowed me to slide the housing on whilst the nut was on by a few threads.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/combeWIP087.jpg
I've also been turning my attention to the underneath of the car as the fuel lines & pump etc will be going back on any day & I wanted the underneath to look nice & presentable, (like a porn starlets undercarriage)!!!
The under side of my car has always been dull & a bit dusty.... I never realised it was body colour under the years of road grime & silt!
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/combeWIP072.jpg
I've seen to painting the gearbox in a coat of Silver & satin Blacked the fr g/box mount as it was unsightly in raw primer. I cut down the studding on the top of the mount too as it was protruding a bit much to look acceptable.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/combeWIP073.jpg
Also; the wiring is all dealt with now, I've got a diagnostic wire left over & I havent put in the speed sender on the box, but the loom plug is ready for some conduit & tucking out the way. Here it is plugged in.... You can see where the main ECU loom enters the car where I've yet to mount the ECU (behind glovebox)
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/combeWIP079.jpg
Speaking of glovebox, the dash & fascia is ready to be installed over the next few days. It will be nice to look inside the car & not see a bare shell & wires for a change. Should feel like its going back together now!
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/combeWIP080.jpg

Will F
03-05-07, 12:40 PM
Who did the pipework matey? Was it expensive? (for PAS)

Where are you mounting the motor?

craig green
03-05-07, 12:44 PM
Hi will.

Pump is mounted in battery tray, next to Corsa master cylinder & servo. I havent secured it with a bracket yet.

I got the pipes from a local hydraulic pipe supplier. Mayflower Hydraulics. Cost me just short of ?70. The ends to fit in the Corsa rack are quite pricey as the metric thread to BSF (or whatever it is) converters cost quite a bit more than if the rack had BSF on it.

Adam
03-05-07, 06:08 PM
Have you started to tackle trying to fit the downpipe to system yet Craig?

craig green
04-05-07, 11:27 AM
Have you started to tackle trying to fit the downpipe to system yet Craig?

All being well my new system will arrive next week, so I will see if it mates upto my 4 branch. If it looks as though it will & the welding required is straightforward, I'll get back to you regards selling the down pipe.

I'll maybe get a pic for you over the weekend anyway.

Last night I fitted the dashboard fascia over all the wiring & I've pretty much sussed how to mount the ECU & Clifford module out of the way.

I also stripped down my driveshafts ready for painting & returning the old CV joints. What a filthy job! Even with full intentions of not making any mess, I still managed to get the grease all over the garage floor, used 4 pairs of surgical gloves & about 12 yards of workshop paper towel + narrowly missed my Mrs getting it all over her trousers! (CV grease that is) :)

Adam
04-05-07, 01:18 PM
Ive got a x16 d/p
Just interested in how people are making the 16v d/p fit nova system.

craig green
04-05-07, 01:26 PM
Ive got a x16 d/p
Just interested in how people are making the 16v d/p fit nova system.

I was told it will mate straight upto a Nova system as its considerably shorter than the C16XE downpipe.

Adam
04-05-07, 01:35 PM
I was told it will mate straight upto a Nova system as its considerably shorter than the C16XE downpipe.
Yeah i heard that too, but i have a sr exhaust system, Lol.

craig green
21-05-07, 03:43 PM
Oops no update for a while.

Dash is in, Speed sender is wired, driveshafts are painted, fr 288mm discs are drilled & fitted but I'm still cleaning the fecking underside. Its coming up nice though.

pics on way.

craig green
21-05-07, 03:51 PM
1 pic LOL

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/combeWIP099.jpg

My new exhaust system looks like it will mate upto the BTB 4 branch nicely, really glad about that. It will need the flange swapping to the over engineered BTB type, but thats not too much of an issue right now.

I need to blag someone to come & do a spot of welding for me. A rather large plate needs putting on the fr chassis leg (under the wheel arch) & I need my rear exhausr hanger welding back on as it was removed during the turreting last summer.

Next hurdle has to be doing the brake lines & plumbing in the PAS.

I also need to fabricate the battery tray, PAS pump bracket & a method to mount the ECU behind the dash.

Timmy
21-05-07, 04:57 PM
work is looking good lad will it be at PVS?

craig green
21-05-07, 05:25 PM
No chance! Bit gutted about it but its never got there in the last 5 yrs, so whats another no show?

I did say it would be at Billing but I've noticed the date & that wont happen either. So at risk of jinxing it for TRAX. It wont be there either!

craig green
24-05-07, 11:47 AM
update with pics!

I got the dash back in a couple weeks ago. Tidied a lot of the alarm wiring in the process & insulated lots of wires & bits of car that can rattle up against each other.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/wip12.jpg

Arty shot of the engine bay as it is.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/wip11.jpg

Lovin my new tail pipe...
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/wip10.jpg

Check the girth on that!
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/wip9.jpg
The perspective is all to f**k so the can looks smaller than the tailpipe - its not!
I bought new Halogen bulbs for my workshop light today (she blew Monday nite)

craig green
25-06-07, 12:00 PM
I've neglected this thread from updates, so I'm pasting it in...

The underneath is beginning to look all nice & Red..
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/STA40003.jpg

Driveshafts are all painted up & new CV joints & boots fitted yesterday.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/STA41161.jpg

Still no rad arrived yet from buypartsby Real good service (not).

craig green
25-06-07, 12:02 PM
The radiator scenario......

VALEO rad is an off the shelf item, but the last one I bought (Serck Marston) was prertty crap tbh. Seeing as the car wont be on the road any day soon I'm not overly bothered about the rad, but I ordered it with the heater matrix & that was fitted over a month ago!

I'm still mincing about painting the underside but soon as its done.. I'm looking forward to clipping up the fuel pipes, fitting my new fuel pump & plumbing in everything fuel related.
I just need to paint a bit more stuff under the passenger side & then move the car in the garage once again, to get to the drivers side (hence fuel pipes etc).
Shafts look really good with the new joints & boots on. (pics soon)
Btw I have actually got bored of pestering buypartsby. Its VALEO that are slow to supply the rad, I think demand has been high of late.

I've got one on order from Halfords now (at retail price I might add)!

craig green
25-06-07, 12:08 PM
Still mincing!
This is a seam accross the rear floor pan infront of the rear seats. It can get pretty crusty if allowed to. I cleaned it back & put in a really thick protective layer of seam sealer along the lip.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress003.jpg


The rear calipers had their final coat of silver & the EBC pads & new pins slotted home.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress028.jpg

I've decided on my colour scheme for the engine bay, so set to it with the Satin Black.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress008.jpg

The radiator saga continues. I've given up on www.buypartsby.co.uk who have taken 3 months to not get one to me. Halfords it is then. Should be here within a week. The front end will be assembled after it arrives including bumper & lights etc.
Today has seen more painting of the underside (see seam sealer shot above) & running the fuel hoses from the fuel rail down to the drivers side floor pan. The pump & lines should go on later this week.
Heres a shot of my work bench after the thread earlier last week on 'benches'. Note the 'dirty' poster on my store room door. Hehe.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress018.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress019.jpg

puss puss
25-06-07, 12:43 PM
just read the whole thread looking good mate keep up the good work nova looking awsome wish i had a garage :(

craig green
25-06-07, 03:56 PM
Thanks chap. I only had a garage since March! So I know what a wind swept driveway is like.

Just had a phone call. Radiator is in stock. Yeeha!

craig green
25-06-07, 10:40 PM
Tonight I was chuffed!

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress038.jpg
Me rad arrived!

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress041.jpg
I checked it fits so I didnt have to return it...

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress037.jpg
Another coat of Satin black on the powerbox. Didnt primer it though & regretting it already..

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress039.jpg

Fuel unions bolted home.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress031.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress032.jpg

Things feel like they are gelling together a bit now

draper
25-06-07, 11:59 PM
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workinprogress038.jpg





wow, this is the biggest rad that looks like a screen we've eveeer fitted



:cool:

craig green
29-06-07, 10:16 AM
Just spent the last 2 nights trying to clean some kind of undeseal substance off from under my rear arches. Its still tacky after a year of being on there & wont allow any other products to be applied. Its just messy as funk & I'm really pissed off with it.

The only thing that seems to shift it is carb cleaner. My hands are a mess, I've used shed loads of workshop tissue & Wednesday night I'd totally had enough. When I shut the garage door I didnt want to see the car again......

craig green
29-06-07, 10:17 AM
Well I spent about 3 hours under the clocksucker last night. 3 empty cans of carb cleaner, 2 ruined toothbrushes & mild neck ache later.... I'm happy with the passenger side wheel well & rear chassis leg. Its dry & free from scummy underseal. Tonight (Fri) should see some nice seam sealer going on after a coat of zinc primer.

Gotta do it all again on the drivers side though! http://www.migweb.co.uk/forums/images/smilies/doh.gif I'm somewhat happier than yesterday though.

matthew172
29-06-07, 10:54 AM
update with pics!

ILovin my new tail pipe...
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/wip10.jpg


what make/model of exhaust is that because i like it alot

gazz
29-06-07, 11:11 AM
it looks the same as what i have matt...
which would be.. piper s/s with 3.5" tail outwardly rolled..
:thumb:

Adam
29-06-07, 01:44 PM
what make/model of exhaust is that because i like it alot
IIRC its a custom system mate, made to fit a small block 16v.

Nice one craig, good to see you got a rad(is it the one from bypartsbuy? Or halfords?) good choice removing the vertical bar that goes between the slam and crossmember, as its a right bastid to get the rad down past the dispak, exhaust manifold etc. Lol

craig green
29-06-07, 01:57 PM
Exhaust is a custom one I bought 2nd hand. Its comparable to the ones on a lot of the N.W Novas. Big 4" outwardly rolled Cossie style tail pipe & nice stainless pipes & welds. I thought it was a JP but have been told they are different. Could be a 'Blue Flame' one, I dunno? I like it though.

The fr panel brace was removed for the Courtenay intercooler that was on there. Obviously no longer fitted. Yeah slipping the rad in was always a biatch when I had to do the head gasket etc.

Adam
29-06-07, 02:42 PM
Exhaust is a custom one I bought 2nd hand. Its comparable to the ones on a lot of the N.W Novas. Big 4" outwardly rolled Cossie style tail pipe & nice stainless pipes & welds. I thought it was a JP but have been told they are different. Could be a 'Blue Flame' one, I dunno? I like it though.

Does look proper quality, just what i was after :( lollollol

craig green
10-07-07, 03:05 PM
Havent done a great deal since last week, got a couple more pics uploaded though.

More rear end action.... Paint is going on as I clean.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/BILLING052.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/BILLING054.jpg

Ive just picked up an exhaust manifold gasket so the front end will begin to be fitted up (bumpers & lamps etc).

craig green
10-07-07, 03:07 PM
Oh and this is a L hand drive bonnet release lever & cable, so I can mount the brake bias valve on the drivers side location.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/BILLING055.jpg

Above the speaker pod.

http://i30.photobucket.com/albums/c323/turbocraig/bits4sale/Novabits4sale024.jpg

Timmy
18-07-07, 10:17 PM
good work lad. keep it up

craig green
21-07-07, 02:20 AM
Still doing bits here & there. Nothing to report as such though. Cleaned out my outer CVs this week & regreased them. (cant afford new ones & they are newish. 10k). Also routed lots of hoses & cables. Found a 1.2i ECU mount will be ideal to mount the C16XE ECU above the glove box. No MDF or forget nails required!

craig green
27-07-07, 02:06 PM
I've got hold of an airbox, C16SE or late GSi non AFM engine, quite rare & new out of the bag fresh , with a Courtenay foam panel filter.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/NOVAFEATURES001.jpg

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/NOVAFEATURES002.jpg

It'll need tweaking to meet the TB nicely, but I think it can work.

Just got some manifold studs & nuts, so I can fit that & I've literally just signed for a strut brace that has been delivered.

Ash
27-07-07, 02:23 PM
Looking good, how far off is it from running? Might be the only nova at the first offical SW meet lol

craig green
27-07-07, 03:02 PM
Looking good, how far off is it from running? Might be the only nova at the first offical SW meet lol

A while off yet. Next year would be a good bet as I doubt I'll put it on the road over the winter. We'll see. The upcoming tasks should actually go a lot quicker than the cleaning & painting I've been doing for last couple months.

RJM25R
28-07-07, 12:11 PM
That exhaust looks the same as my JP one.....

Ste L
28-07-07, 12:15 PM
air box isn't that rare, they come on sri's too..

maybe rare is, due to most people chucking them in the bin, in favour of a cone filter :roll:


its coming to gether now, look's good :thumb:

SRimon
28-07-07, 12:33 PM
Nice progress Craig, gonna colour code your inner arches?

craig green
29-07-07, 12:19 AM
air box isn't that rare, they come on sri's too..




its coming to gether now, look's good :thumb:

Yeah I meant rare as in . Tricky to come by.



Nice progress Craig, gonna colour code your inner arches?

;)

I think the exhaust is a JP but cant confirm it.. so wont brag. LOL

Mike
29-07-07, 10:12 AM
oooh, looks like its getting there Craig :D nice one for the tip off about that engine in Cov aswell mate :thumb:

Just a quick qeustion, what do you have planned for you washer bottle? As i see youve removed the mounting bracket?

craig green
30-07-07, 01:10 PM
Cheers dude.

Corsa bottle in the scuttle tray. Needs some support to mount on, but an easy solution hopefully. I'll get a pic sometime.

Mike
30-07-07, 09:40 PM
Cheers dude.

Corsa bottle in the scuttle tray. Needs some support to mount on, but an easy solution hopefully. I'll get a pic sometime.

Aaaah good plan!! Ive got a Mk1 Clio bottle knocking about here, just finding a pair of Pug 409 wiper arms is proving quite hard lol

craig green
01-08-07, 10:37 PM
409! 406? surely.

Heres the Corsa bottle in place.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Progress-sale004.jpg

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Progress-sale006.jpg

I picked up exhaust manifold studs & the copper nuts from Vauxhall today. Crack on with front end assembly now.

Mike
01-08-07, 10:55 PM
hey that looks pretty good Craig :D

Ahh, 409 wipers are special ;) the 406 ones are different :D had a look today an cant find my Clio bottle, think i binned it :( but i got a corsa sitting outside......

craig green
01-08-07, 11:56 PM
Never heard of a 409..

Its coming together a bit more now. I've got my strut brace so I can drill the holes to route the PAS pipes through the firewall.

Still need to buy up all the brake lines which is a ball ache for me!

Adam
02-08-07, 12:22 AM
Liking the corsa wash tank,hmm, good idea.
That gives somewhere to fit a catch tank with the washer one gone,Lol.

Does it clear the wiper linkage?

Ash
02-08-07, 01:39 AM
motoring on now! I remember hearing that local motor factors will make up brake lines for you if you give them a template. I know your lines are ending up somewhere differant but you could get them to make them so far and finish of the rest yourself on the car, if they leave a meter or so spare. Failing that, grow a money tree and buy full braided ;)

Washer bottle looks spot on btw. Good work

Mike
02-08-07, 10:11 AM
Never heard of a 409..

LMFAO neither have i lol its mean to say 405 lol

craig green
02-08-07, 10:18 AM
Failing that, grow a money tree and buy full braided ;)

Washer bottle looks spot on btw. Good work

That is the plan.... seedling has just poked through the soil!

Thanks. :)

craig green
17-08-07, 09:36 PM
Nothing much to report other than I removed the tie bar & TCA so I can set about getting the last nut off I've rounded off. The ones going through the ball joints etc.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Progress-sale015.jpg

Its the hole to the right (inside one) thats got the rounded nut in. Minimal accesss with limited tools.
I've taken the dremel to the holes & opened them up where needed as the plates are a tad skew-wiff, thats the issue with the rounded nut.

Other News; I got hold of a pair of small rosejoints to use for my alternator tension adjuster.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Progress-sale022.jpg

Another one of those problems that I was avoiding as I wanted a neat solution.

Lee
17-08-07, 09:38 PM
Thats a good idea on the Alternator craig, thatll make it uber easy to set up on your own, rather than the 3 tools 2 hands normal effort lol

craig green
17-08-07, 09:38 PM
Did I mention my exhaust manifold is on? With new GM studs & copper nuts.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Progress-sale023.jpg

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Progress-sale020.jpg

luke langton
18-08-07, 07:44 PM
It looks like its coming along nicely, some good mods you got there. when she out on the road!

Adam
18-08-07, 09:09 PM
Im liking the rj alternator tensioner, cool solution. Where did you get the joints from?
Manifold looks cool, i'd move the lambda tho.

craig green
22-08-07, 05:26 PM
Rose joints are from my local rally/motorsport stockist. Cost me a fiver for both!

You can get them on ebay & places like Rally Design do them too. I got them by chance really. I was pricing up a Tran-X diff. I just need to get a couple belts to calculate the length of adjustability etc.

One is L/hand threaded & the other is a normal R/hand thread, so by turning the centre one way it will shorten the adjuster & likewise visa versa.

craig green
11-09-07, 10:49 AM
OK. Had a busy weekend doing other stuff & going to Eurofest at Castle Combe (top time as always).
But I also managed a few hours in the garage.
I put a few coats of gloss black on my bottom arms (TCA's) & the tie bars & also put 1 coat of smooth Hammerite in the front wheel arch. I put some seam sealer around edges & joins that form a water trap. Should help keep any water out of box sections etc.

Tiebar & brkt.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/dscn2140.jpg

Bottom arm.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/DSCN2138.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/DSCN2139.jpg

1st coat of paint in wheelarch.
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/DSCN2143.jpg
1st coat looks pretty crap as it doesnt cover very well. (2nd coat is now on).

Hopefully I will assemble the tie bars & TCA's with the new bottom ball joints later tonight & fasten it all back in place with the passenger side driveshaft & new gearbox, d/shaft seals.

craig green
11-09-07, 01:08 PM
Pics of 2nd coat of paint, better coverage & the paint loses its transparency.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/dscn2147.jpg

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/DSCN2145.jpg

tom_beverley
11-09-07, 01:11 PM
Coming along nicely Craig, nice work. Great idea with the alternator tensioner. Safely completed in time for next year then, much else to do?

It would be nice to see pics of the painted inner arches as I'm thinking of doing mine but didn't know if it would look too red...

EDIT- Looks a lot better than the 1st coat, you may have made up my mind lol

craig green
11-09-07, 01:19 PM
I was in two minds wether to paint the inner arches Red or re-do them Black, however the floor pan ended up being done Red as it was already Red from the factory anyway, so it all got a few coats of smootherite in the end.

I just need an alt belt to calculate the min & max movement for the adjuster & then I'll draw up the adjuster bar & get a local machinist to make it up. (hopefully they will have an M8 L/hand tap)

I really want the car ready before the spring, hopefully have it shaken down & MOT'd before I want to start using it. I've been to a few track days recently as a spectator & I'm fed up of feeling left out, plus I need to lose my track virginity soon. I've been wanting to start doing track days for years but money issues & reliability seem to always get in the way. Obviously next year is a key year for Nova enthusiasts & I'm not going to miss it for the world.

tom_beverley
11-09-07, 01:35 PM
Totally agree mate, just watching the vids of everyone going round at eurofest really made me want to get the car finished so I can participate! Its annoying at the moment as mine is still getting welded up so I can't do anything really which gets a bit frustrating!

Like yourself I was stuck between red and black for the inner arches. Red looks the best choice though, definately a damn sight better/cleaner than it was! A lot of time spent prepping and painting I bet :)

craig green
11-09-07, 02:29 PM
Totally agree mate, just watching the vids of everyone going round at eurofest really made me want to get the car finished so I can participate!

A lot of time spent prepping and painting I bet

Yeah track days look like mucho fun. Some good friends to be made there too.

I feel like I've been on my back painting the floor for ever. Rear wheel arches are in primer still!

craig green
18-09-07, 03:55 PM
Nearly finished in that corner.

Theres about 4 coats of Red Smootherite Red on there to cover up the Black that was on there.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/dscn2150.jpg
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/DSCN2148.jpg

I will start on cleaning up the KONI struts too, nothing major to do with them but I have realised they are a minging shade of Yellow next to the other bits I've done. I'm tempted to put a coat of nicer Yellow (RAL 1018) on them & freshen them up. I want some GAZ coilovers when money allows though & I've got some billet top mounts on the way hopefully..

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/DSCN2151.jpg

tom_beverley
18-09-07, 04:02 PM
Looks fappin lovely that Craig, definately on my list of things to do :p

Lee
18-09-07, 04:03 PM
I'm fed up of feeling left out

reliability seem to always get in the way. .

Lets start a club lol


Looking good craig! SHould be flying around together next year hopefully :thumb:

Adam
18-09-07, 04:26 PM
Arches are looking cool now, with a few extra coats on

craig green
18-09-07, 04:48 PM
Thanks guys, motivation has been on the up in last few weeks, what with Llandow & Eurofest just passed.

Hopefully in the next few days I'll have her turned around in the garage so I can work on the drivers side & mount all the fuel lines & maybe look to turning the key one of these days. See if this engine works? lol

Jeff16v
18-09-07, 05:33 PM
Nice painting Craig, did you scrup off all the underseal or just paint over. I need to do all my arches shiny instead of matt.

You might even get to a show next year at this rate!

scott.parker
18-09-07, 05:35 PM
Looks top craig, just wondering why did you sell the turbo lump?

Scott

craig green
18-09-07, 05:37 PM
I painted over the underseal which was scrubbed clean.

I sold the turbo engine as I had money troubles & intended to break the whole car, that went 1st but I then changed plans as no one wanted the shell. I saved it from the brink of scrapping. LOL

Wish I still had that engine, really craving some small block boost tbh.

valver500
18-09-07, 05:41 PM
Hi Craig nice project coming along there mate!
Just wandered what was the idea of the bolts going through the hole in the inner wing where the track control arm passes through?

craig green
18-09-07, 09:34 PM
Cheers.

I just wanted to fill the holes, I'm going to cut some ally plate to the shape & sandwich some rubber between it & the innerwing to create a weather guard, Stop puddle splashes getting the bay filthy.

Where abouts are you from in SW dude?

valver500
18-09-07, 09:54 PM
Ah right always wondered if vauxhall ever made a rubber guard for that hole? :confused:
Im in the Weymouth area Craig:thumb: where abouts are u?

craig green
20-09-07, 08:38 PM
no they havent made a dirt shield as far as I know.

Bridgwater mate. (join up)

scott.parker
20-09-07, 09:26 PM
Cheers.

I just wanted to fill the holes, I'm going to cut some ally plate to the shape & sandwich some rubber between it & the innerwing to create a weather guard, Stop puddle splashes getting the bay filthy.

Where abouts are you from in SW dude?

Thats a top idea Craig...Never seen it done before iether :thumb:

Make a kit and then see if you can reproduce it cheep enough,start selling them.;)

Scott

Andy_L
20-09-07, 10:26 PM
Craig whell arches look fappin brilliant :thumb:

Keep it up mate I can't wait to see it once it's finished.

craig green
21-09-07, 12:50 PM
Thanks mate. Your welcome to have a look anytime. (you are in my neck of the woods)

Andy_L
21-09-07, 01:25 PM
Thanks matey I will sometime soon.

I'll PM you about what biscuits I'll need to bring lol

Aamir
21-09-07, 04:22 PM
I just wanted to fill the holes, I'm going to cut some ally plate to the shape & sandwich some rubber between it & the innerwing to create a weather guard, Stop puddle splashes getting the bay filthy.

As they say..."Necessity is the mother of invention"

Neat idea :thumb: :thumb: :thumb: :thumb: :cool:
I'm off to make a mirror polished stainless steel one :D http://www.jeepsunlimited.com/forums/images/smilies/bling.gif it'll look nice against my chrome driveshafts & steering rack !

craig green
21-09-07, 04:29 PM
Hmmm. Well ally polishes up nicely & I do have the rubber to do it.

Oh & my shafts are Yellow btw!

craig green
28-09-07, 11:40 AM
I'm all excited! Just won some seats on ebay!

This week I've been painting up the tie bar & TCA etc from the drivers side & am trying to get the car ready to wheel out the garage to turn around.
Didnt get much done last weekend as I was scrapping my old Luxe + Nova. R.I.P. (pics may follow)

The Mantzel plenum is bolted down with the gasket I made & a new VALEO headlamp arrived I won on ebay. ?7.99, of which ?5.00 was postage. BARGAIN! So just need to order 1 new headlamp & I have new indicators I bought years ago.

The fr end is slowly coming together. Rad is in with the Samco's, I need all new Jubilee clips on all hoses though.

Jeff16v
28-09-07, 12:10 PM
What seats did you get, any pics or links?

craig green
28-09-07, 12:18 PM
Mk5 Escort RS2000 Recaro's.

Try putting in the item number... 220152539048

draper
28-09-07, 12:19 PM
how long till its done then craig ??

craig green
28-09-07, 12:21 PM
2012

draper
28-09-07, 12:21 PM
so soon, your really going for it then ;)

Jeff16v
28-09-07, 12:31 PM
Nice seats, SPANKDAMONKEElol

Bargain!

big gra
28-09-07, 12:32 PM
reallg good idea with the alternator adjuster, i was thinking of doing something like that!

craig green
28-09-07, 12:32 PM
Haha. I wanted it to be at PV this year & tbh its still no closer, yet I've put in a lot of hours since.

I wish I'd spent more time last year sprucing up all the parts that go back on, most of the work is renovating parts like hubs, tie bars, painting the floor pan etc.

Its getting there. As said when I get to turn it araond in the garage, things should really happen as I can work on th edrivers side by installing the fuel lines, fuel pump & generally work towards starting her up!

Anyone wanna witness a 16XE fire up off a bare 4 branch BTB manifold?

As I have limited tools aswell, things that need fabricating are taking a back seat, stuff like welding the custom modded battery tray, the alternator adjuster, a bracket to hold the PAS pump steady etc.

If it doesnt make the shows next year, no one on here will ever hear from me again & I will slide away into depression.

craig green
28-09-07, 12:34 PM
SPANKDAMONKEElol



Damn! My secret pastime is no longer secret! :D

tom_beverley
28-09-07, 01:26 PM
If it doesnt make the shows next year, no one on here will ever hear from me again & I will slide away into depression.

Well you better get a bloody move on then lol

I know what your mean as I've done a few renevation bits and you seem to nowhere fast if at all! Now you've nearly finished those bits things should come along quite nicely, thus maintaining the motivation lol

Look forward to seeing it started for the first time mate.

Aamir
28-09-07, 01:56 PM
If it doesnt make the shows next year, no one on here will ever hear from me again

I couldn't take mine to the shows this year due to running problems, but hope to see you at most of them next year.

craig green
28-09-07, 02:40 PM
Next year should be great. I think I'll get it to the 1st Action day at Combe which will be my 1st track day anyway, so hopefully I'll take it steady & she'll get through it in 1 peice. Then the shows start - PV & Billing etc & after that I'll sign it up for all the track days going.

Tom, yours was maybe going to PV aswell wasnt it? LOL

Aamir, really looking forward to seeing your car in person.

Adam
28-09-07, 03:02 PM
Better get a move on, else you'll be sitting here next May rushing to sort it for Pv :p Lol

Ste L
28-09-07, 03:10 PM
Aamir, really looking forward to seeing your car in person.


it's a really stunning nova, seen it a few week's back, when i sorted the engine loom on it :thumb:

craig green
28-09-07, 03:17 PM
Better get a move on, else you'll be sitting here next May rushing to sort it for Pv :p Lol

Cheeky get! :thumb:

Adam
28-09-07, 03:29 PM
Lol

Do you have a list of whats left to do?

Rick Draper
28-09-07, 03:32 PM
Craig did the light come with the rubber boot that covers the hole around the bulb?

craig green
28-09-07, 04:46 PM
Craig did the light come with the rubber boot that covers the hole around the bulb?

Yeah. I've got spares mate funnily enough.

craig green
28-09-07, 04:51 PM
List of things to do.....

I've written it down so many times, but just cant stick to it. I see something I feel like doing & do it, buy something that can be fitted & fit it.

bump
28-09-07, 07:06 PM
It's looking good mate, much better than when I poked my head under lol

Keep it going over the winter.

craig green
30-09-07, 07:36 PM
It's looking good mate, much better than when I poked my head under lol

Keep it going over the winter.

Need a little welding doing if you are up for it in exchange for beer tokens?

Might PM you. :thumb:

craig green
02-10-07, 05:08 PM
I was a busy boy last night. Other tie bar is painted & the passenger fr corner now has, knuckle, strut, driveshaft, disc, pads & caliper assembled.

Tonight I want to try & have it ready to push out in the street to turn around. Gonna give it a wash whilst its out too.

craig green
03-10-07, 06:27 PM
Just a pic of the Tie bar & TCA's painted...

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/TDbuild001.jpg

And the driveshaft seals I fitted to the F15 gearbox. (old ones a pig to remove)
http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/TDbuild006.jpg

Still not rolled her out... Weekend I expect!

peester
03-10-07, 06:44 PM
foook! some graft goin on here.. getting really stuck in the detailing cg..
All good; most satisfying.

alan b
04-10-07, 09:47 AM
looks good man will be amazing when its done, what size those nuts and bolts you used around the steering arms holes? in the inner wing?

craig green
04-10-07, 10:12 AM
Thanks chaps. My Mrs has hardly seen me this week. Spent 3 hours getting high on carb cleaner last night (I mean cleaning the TB & AFM) LOL

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/campics2014.jpg

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/campics2015.jpg

I got a bit disheartened at the end though (comedown?) The AFM doesnt fit after the TB as the turret is in the way, I looked through some old TV mags & found a pic of Chris Searles Mantzel'd Nova & I think I need to extend the AFM plug wires by about 3 inches & mount the AFM further away. That means buying some Samco reducing bends. GREAT!

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/campics2019.jpg

On another note, I hooked up the accelerator cable that came with the engine & didnt like the feel, very heavy. So tried a std Nova GTE cable which about 3 feet shorter & it felt miles better, chuffed it fitted too as not all cable ends are the same!

Stainless fasteners are; M5 x 16 with 'A' form washers & nylock nuts.

Ash
05-10-07, 09:21 PM
cool, really cracking on with it now then. It take forever cleaning and painting, but the results easily speak for themselves.

BTW, alway a shame when you HAVE TO but Samco :roll: lol

craig green
06-10-07, 06:06 PM
Not sure I get what you mean by 'Samco' Ash, but it looks as though I need a Cav TD inlet hose. I spoke to a Samco supplier anyway & they dont make 45 degree(?) reducers.

I've put the drivers side tie bar & TCA on so tomorrow if I can be bothered, will be wheeling her out & turning it around to start work on fitting the fuel system & painting the arches on that side.

Ash
06-10-07, 07:04 PM
lol sorry I was incrediably tired when I wrote that. I meant it's a shame to have to buy nice looking bits, jokingly.


BTW, It's always a shame when you HAVE TO buy Samco (or any other go faster parts):roll: lol

craig green
07-10-07, 12:41 PM
Ahh right. Well I'd rather not tbh. Samco is a bit overkill IMO for what I want & peicing bits together involves internal joiners which will decrease the pipe size, so restricting it. Just not an option really.

It would appear there is a GM hose from a Cavalier TD that will do the trick. Fingers crossed.

scott.parker
07-10-07, 01:55 PM
Humm Craig is the hose/pipe you need something a bit like what use to be on my car when i runing it with a power cap?

Like this.

http://img232.imageshack.us/img232/6330/picture405smallkc2.jpg

Scott

Mike
07-10-07, 02:53 PM
Doh, i had a piece of blue samco style hose like that knocking about aswell Craig

craig green
08-10-07, 01:53 PM
Scott, yes & NO.

Your powercap (SFi) is already half pointing in the right direction, where as my TB is closer to th eturret & not at an ideal angle. Its also different sizes either end. Like I say it should be sorted fingers crossed.

Need a new outer CV joint aswell, as one just wont clean out, it feels notchy.

craig green
12-10-07, 10:54 PM
No updates as I'm feeling totally under the weather currently. Been off work since Tuesday with tonsilitis. I ache all over too, like FLU.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/campics2023.jpg

Little pic I took t'other day.

big gra
13-10-07, 11:49 PM
whats the spec of the engine???

looking really good so far!!

craig green
17-10-07, 01:41 PM
Cheers mate, engine (C16XE) has Mantzel powerbox, Schrick cams & BTB 4 branch tubular manifold. I'll hopefully get a remapped UCU for it & I think it will need a cone filter as the airbox I have just wont be any use I think. My preferred cone filter is the pipercross vector type ones.

It'll have a juicy, new Walbro uprated fuel pump on it too.

craig green
17-10-07, 01:47 PM
Just compiling a little list of the next couple jobs I want to do;

Build a rosejointed gear linkage (not going to quick shift it just yet).
Purchase new Jubilee clips for entire coolant system.
Buy & fit new drivers headlamp....
Fit radiator grille, front bumper, splitter etc
Paint wiper arms, buy new blades.
Drop rear beam, dis-assemble & powder coat etc.

Few things to be getting on with!

Adam
17-10-07, 02:06 PM
Cool, not too much then :)

Aamir
17-10-07, 02:32 PM
I got a bit disheartened at the end though (comedown?) The AFM doesnt fit after the TB as the turret is in the way, I looked through some old TV mags & found a pic of Chris Searles Mantzel'd Nova & I think I need to extend the AFM plug wires by about 3 inches & mount the AFM further away. That means buying some Samco reducing bends. GREAT!

I hade a late 1.6i in my gsi, it didn't use an AFM, why not just use a late loom & ecu & bin the AFM ? (or is it not as simple as that?)

From what I'm told the AFM is the most restrictive part of the inlet !

Adam
17-10-07, 02:40 PM
Not as simple as that.
A lot of work to convert it to a X16xe engine(map sensor)

Ash
17-10-07, 09:02 PM
Build a rosejointed gear linkage (not going to quick shift it just yet).


I seem to remember R/J'ing and quickshift don't work, maybe someone can confirm...

Will be mint when it's done, any news on the 'steering rack arm cover type things'

Also has it had a respray or has it just stayed red since it came off the road?

craig green
17-10-07, 09:07 PM
LOL, cant afford a respray, its got a nice colour but the paint seems to have blistered on the roof like a mates did that was sprayed by the same painter (fecking nonce). I'm gonna have the roof & bonnet + bumpers redone I expect & maybe put another drivers door on + I'm hoping to get a pair of new quarters which will go on in the future.

Switching to X16 loom & sensors seems daft tbh, the AFM on these isnt a flap type like older engines, so I fail to see how its much of a restriction, the actual TB seems pretty small to me though.

Also Adam, thats not a list to finish it! Just next few jobs I've highlighted.

Glad to say I'm better now & over the dreaded tonsilitis, I was so ill last week!

krobinson
17-10-07, 09:08 PM
Its all looking very very tasty now craig, The finish it near and I bet you cant wait to thrash it :)

Do you think you'll ever turbo the XE?

Lee
17-10-07, 09:15 PM
I seem to remember R/J'ing and quickshift don't work, maybe someone can confirm...



it should do, as its only the horseshoe part thats different on a QS linkage, therefore rosejointing that should work wonders IMO


Looking good craig, home stretch now :)

craig green
17-10-07, 09:18 PM
Still a lot to do, yeah Keith, I'll buy another C16 & bolt the Corsa VXR manifold & turbo to it. Main issue is findong some pistons to lower the CR but tbh thats another project in itself. I do just want to thrash this tbh.

Get my monies worth & have some fun with you guys!

Timmy
17-10-07, 10:22 PM
Get my monies worth & have some fun with you guys!
couldn't of said it better my slef

scott.parker
17-10-07, 10:36 PM
LOL, cant afford a respray, its got a nice colour but the paint seems to have blistered on the roof like a mates did that was sprayed by the same painter (fecking nonce). I'm gonna have the roof & bonnet + bumpers redone I expect & maybe put another drivers door on + I'm hoping to get a pair of new quarters which will go on in the future.


The silky had micro blistering on roof and bonnet, its when a car is left to dry in normal air not in an oven, as it drys moisture builds under the paint, and then in time works its way through to the surface!! Grr:roll:

Keep up the good work though dude.

Scott

craig green
18-10-07, 09:23 AM
It was oven baked though..... (odd)

Aamir
18-10-07, 09:46 AM
Not as simple as that.
A lot of work to convert it to a X16xe engine(map sensor)

Isn't the X16xe a 16v engine ?

craig green
18-10-07, 09:50 AM
Yes, but I guess although the block & head are essentially the same, the X16 which is later type is somewhat more different in terms of ECU system & loom etc, plus it has all the EGR gubbins aswell which is ECU related.

Not quite as good an engine according to most people from a tuning point of view.

Aamir
18-10-07, 09:53 AM
Well mine was an 8v that didn't use an AFM, just thought i'd clear that up

Adam
18-10-07, 11:10 AM
Dont know if im stating the obvious here, but he has a 16v 1600, not 8v....

8v without a afm, was a C16se

craig green
18-10-07, 01:36 PM
Well spotted Adam..

Small update/pic opportunity.

One morning last week me & a buddy pushed her out into the street & turned it around to manouvre back into the garage rear end first.

Front end from out in the street...

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


One new headlamp & indicator in place.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/frontEND2.jpg

Headlamp was an ebay bargain at ?3 + ?5 for postage. Genuine Valeo unit.


I've got these new captive nuts from Vauxhall to mount the fuel pump assembly, same as whats used as std, just mine wewre well rusted & cut iut during the chassis leg repairs.

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


Also picked up various new nuts & bolts for the bottom arms (TCA's) & tie bar brackets.

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

Should be cracking on again over the next few nights & weekend now that I'm feeling better.

vaughanmc
18-10-07, 03:10 PM
Looks good seeing it all painted up and 1/2 built back together

Is there much more to go on the build??

craig green
18-10-07, 04:58 PM
Mainly small stuff like fuel system, gear linkage, bumpers, brake lines & other stuff I can't remember.

Adam
18-10-07, 05:08 PM
Looking good, liking the bonnet vents.

macc nova
18-10-07, 05:32 PM
lookin good mate, pmsl at the wood on the floor so you dont have to lie down on the concrete. lol

scott.parker
18-10-07, 07:36 PM
It was oven baked though..... (odd)

Oh right, well it's a nova anything is possible! lol

craig green
19-10-07, 10:32 AM
lookin good mate, pmsl at the wood on the floor so you dont have to lie down on the concrete. lol

Its kitchen floor vinyl, there is offcuts of carpet & about 4 Nova boot carpets on my garage floor. lol


Scott, So true! :confused:

GRUNT 16V
23-10-07, 01:09 PM
Looks almost as good as mine Craig!!!!lol
Just joking looking good !! cant wait ti see it finished !! also thanks for posting up the pics of my Nova on mig!!:thumb:

Mike
23-10-07, 01:14 PM
looking top Craig :D

Come PV & Billing, it should be looking spanking :D

craig green
23-10-07, 01:56 PM
Thanks Grant, no problem, though I wish my paintwork was as sweet as yours. Respray #2 in the pipeline!

PV actually feels too close for comfort tbh. (did I really type that in October?)


I stripped the subframes off the seats lastnight, I can see why matey got rid, the std Ford subframes had snapped on one side, luckily the Recaro seat is fine. It was a Ford part that failed. Heheh.

I was under the back end of the car for about 2 hours solid last night. Cleaning off the Schultz nonsense from the drivers side rear turret, should have the back end fully painted out by the end of the week hopefully, that will leave the way clear for the refurbed rear beam to be fitted with the new GM bushes (I might regret not using split type poly bushes). Cant wait.
Beam is yet to be refurbed btw.

Ash
23-10-07, 06:21 PM
PV actually feels too close for comfort tbh. (did I really type that in October?)


Just to comfort you, mine WILL be at PV08 finished, you got nothing to worry aboutlol

craig green
01-11-07, 06:30 PM
Lost some enthusiasm recently;

However, spent yesterday afternoon taking the rear beam off. So I can get better access for the last bits of cleaning & painting underneath.

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

Once thats done, the tank will be going on & in the mean time the rear beam will be wire-drilled, primered & painted etc.

krobinson
01-11-07, 07:11 PM
Good work craig, its hard to get the motivation this time of year. But keep it up!

craig green
02-11-07, 06:19 PM
Cheers Keith. I actually spent over an hour last night cleaning the beam & trying to get the ARB out of it. It was a bit like unearthing some archaeology... I found a date stamp on the beam.

29 AUG 89. I was quite surprised as all the interior plastics & mouldings etc indicate mine as being 1 of the 1st GSi's I'd guess? Being September '90 which was when they were launched. I assume the beam's were made in massive numbers previously...

Useless trivia!

craig green
03-11-07, 02:49 AM
A bit more proof the beam is off...

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workpicswestfest014.jpg

Its a bit cleaner, but struggling to pull the feckin ARB out. Through the other side maybe?

Heres a chassis leg awaiting Hammerite.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/workpicswestfest013.jpg

Adam
03-11-07, 12:33 PM
Nice work.
Chassis leg looks nice and solid :)

peester
03-11-07, 01:48 PM
that rear beam will look satifyingly good once repainted, cleaned up.