Nova C20LET

[Rob77]

Hi guys, its been a while since I posted any progress on my car, and I've been a busy bee over Christmas, so I thought I would update!

For those of you who don't know my car, it looked like this before Christmas:

http://www.novaload.net/forum/showthread.php?t=68002 (Had a standard 20XE, with f20 box fitted with a plate diff)

But I decided to go for LET power, so set about the swap over Christmas...

The LET engine in question (was standard when bought):

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000017.jpg

Uprated actuator, Magnecor leads, FPR take off, and Saab reds fitted before it went in:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000021.jpg

Gearbox mount drilled and tapped, and mount fitted:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000023.jpg

2WD conversion plate fitted:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000025.jpg

XE out, LET on crane ready to line the passenger side gearbox mount up: (Note original Nova mount had been chopped off at this point)

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000049.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000051.jpg

All level and square, and ready to mark up (Other two engine mounts bolted up, gearbox on a jack):

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000053.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000054.jpg

[Rob77]

Gearbox mount welded on the chassis rail, and etch primered:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000063.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000064.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000065.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000066.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000067.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000068.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000069.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000070.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000071.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000072.jpg

[Rob77]

Bay painted white:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000084.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000083.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000085.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000087.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000088.jpg

I wanted to use a Nova TAS drivers side mount for the passenger side gearbox mount, as I have TAS mounts on the other two.

I knew it was going to be a nightmare, as space was so tight that the head of the bolt that connects the TAS mount to the gearbox mount would not fit behind the TAS mount and the chassis rail!

I ground down some of the head of the bolt, trimmed down the back of the TAS mount a bit, and amazingly it JUST squeezed in!

(Can you tell I painted everything while holding it... Pro job!)

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000073.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000075.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000076.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000077.jpg

Just see the head of the bolt when viewed at an angle:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000078.jpg

[Rob77]

Nice rust free headlamp holes!

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000089.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000090.jpg

Engine all bolted in!

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000127.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000126.jpg

Few bits in the bay:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000131.jpg

Mount all in place: (I need to paint those nuts and washers!!!)

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000133.jpg

[Rob77]

Had to trim the front pannel level with the chassis rails, then weld the two skins back together, to allow room for the 3" boost pipes:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000197.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000198.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000199.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000213.jpg

Regal uprated rod bolts fitted:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000202.jpg

Cork gasket remains all cleaned off: (NIGHTMARE OF A TASK!!!)

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000210.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000211.jpg

Nice clean sump:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000205.jpg

Bit of silver paint:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000208.jpg

8V baffle plate with built in gaskets:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000209.jpg

Will be annoyed if the sump leaks!!!

[Rob77]

Nova GSi bumper destroyed to fit intercooler in: :cry:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000214.jpg

(I will be cutting away the lower pannel and rewelding it to allow the cooler to sit further back once its running, and then buying a fibreglass GSi front bumper to get a bit of weight loss)

Boost pipes being aranged: (Note the genuine HKS SSQV BOV :thumb:)

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000216.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000217.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000220.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000218.jpg

Rad and two 10" slimline fans being mocked up:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000221.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000223.jpg

Intercooler mounting being sorted:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000226.jpg

[Rob77]

Thats as far as I have got so far, as the car is in Nottingham, and i am back at uni in Birmingham, in my final year, so am struggling to find the time to get the train home to work on it!

Not much left to do now though...

[Chris]

what management is that going to be run on?

What the idea behind the huge intercooler and boost pipes?

[draper]

good work there fella, loved the car when it was XE'd but whats the deal with that hoooge chavvy (imo) intercooler ??

[Will F]

lol
That i/c and pipe work is interesting!

[Rob77]

what management is that going to be run on?

What the idea behind the huge intercooler and boost pipes?

I am using the Evo5 Vmax chips at first, with the view to move to a "proper" management system when the engine is beefed up a bit.

I am awaiting one of the 3" top hats from the group buy on MigWeb (the one from Scooby), and so I wanted the pipework and FMIC to match (3").

It seemed daft to not buy 3" tubing now, only to want it in the future, so yes I know it is a bit overkill with the standard turbo, but will be upgrading in the near future to the 200sx manifold and a bigger turbo. (Unsure of what yet though... T34 / T4 etc)


I managed to get Corsanova his tophat modified and made up due to him having his car rolling roaded and we wanted to see the before and after results of the tophat. Anyway to cut a long story short here are the results.......
Before:
283bhp/312lbs torque
After with 3" tophat fitted and 60mm pipework:
294bhp/318lbs torque
No bad considering he's only running a std turbo which was near max capacity. With a larger turbo you could see the tophat come into it element and produce more bhp.
Very pleased and surprised at the results :D

I am fairly sure Dan-J from here with the white Nova turbo was / is planning to run the 3" pipework with his T3 setup, so I thought I may as well get involved too!

I know I am going to get a bit of a slaying with the intercooler as it IS a bit chavvy, but it is not that much bigger in volume than the Frontera jobbie, and my main reason for choosing it was I got it for a good price (?80 brand new), and it has 3" in/outlets.

I will be hiding it behind the bumper very soon though, as I want the car to remain a "sleeper" kind of thing!

Rob.

[Paul]

It similar size to my Evo one which is too big apparatnely according to all the smart ****s on here,

However correct me if I'm wrong but Evo's run 240-400 bhp all on same intercooler, and ohh look what smarties mines inbetween them figures, and so's Rob's.

Some people think they know what theyre talking about and just don't, ROb mate just ignore them. That I/C's fine, better than having 50deg boost temp.

Good progress mate

[Rob77]

It similar size to my Evo one which is too big apparatnely according to all the smart ****s on here,

However correct me if I'm wrong but Evo's run 240-400 bhp all on same intercooler, and ohh look what smarties mines inbetween them figures, and so's Rob's.

Some people think they know what theyre talking about and just don't, ROb mate just ignore them. That I/C's fine, better than having 50deg boost temp.

Good progress mate

Cheers mate!

[SRlew]

looking good matem never seen 3" pipes used.

[Adam]

Its going be difficult hide that IC behind the bumper....

Good work tho Rob, looking cool. :)

[ANDYRACER]

I have to agree that the i/c looks way to big imo.
But i guess in the future you could get a custom one made up to the same size as a frontera one cos they seem to fit fairly well behind the bumper.

Looks good tho mate, :thumb:

[Rob77]

As said, the IC isn't much bigger than the frontera one really.

Frontera is = 600 x 210 x 40mm

Mine is = 450 x 300 x 75mm

I suppose mine looks bigger as it is more of a square, than a rectangle (if that makes sense), plus its on show and very shiney!

Am debating painting it matt black, better heat transfer and more stealth!

Rob.

[ANDYRACER]

If your planning on putting some mesh etc in front of the intercooler then paint it, if not dont.
When painted black they get stone chips and look crap.

[Rob77]

If your planning on putting some mesh etc in front of the intercooler then paint it, if not dont.
When painted black they get stone chips and look crap.

Good idea, not thought of that.

Rob.

[ANDYRACER]

Zafira gsi grill the front bumper for the factory (sleeper) look. :thumb:

[Rob77]

Do you mean the honey combe stuff?

[graham kirkbride]

well done Rob looks cracking mate

[draper]

bit of a hijack BUT are you coming to the east mids meet either of you pair above ???

[Rob77]

bit of a hijack BUT are you coming to the east mids meet either of you pair above ???

When / where etc!

[mikey14sr]

I've seen bigger i/c's on smaller engines with little detrimental effect, the cooler you can get the charge air the better really.

[R1CH]

Looks like its coming on ... have you spaced the rear gear box mount ? Usually theres a spacer with an extra hole so you can get the mount bolted up with 3 bolts, i made a plate to fit then welded it to the origional mount.
3" boost pipes = Lag tastic !! lol

http://i6.photobucket.com/albums/y221/ricmetcalf/Nova%20build%20pics/DSC00385-1.jpg

Rich

[JSeymour]

i must be a chav because i like big fmic'slol! good work mate, keep us posted.

[Rob77]

Looks like its coming on ... have you spaced the rear gear box mount ? Usually theres a spacer with an extra hole so you can get the mount bolted up with 3 bolts, i made a plate to fit then welded it to the origional mount.
3" boost pipes = Lag tastic !! lol

http://i6.photobucket.com/albums/y221/ricmetcalf/Nova%20build%20pics/DSC00385-1.jpg

Rich

Yes mate have spaced the rear, but it only came with a spacer plate with 2 holes, and two bolts... You think I need the 3 in to be safe?

Think the lag will be much though?

Can't imagine a huge difference in lag between the 76mm tubing I've used, and the 60mm tubing usually used as an upgrade.

Rob.

[Rob77]

i must be a chav because i like big fmic'slol! good work mate, keep us posted.

Cheers mate, will do!

[R1CH]

Yes mate have spaced the rear, but it only came with a spacer plate with 2 holes, and two bolts... You think I need the 3 in to be safe?

Think the lag will be much though?

Can't imagine a huge difference in lag between the 76mm tubing I've used, and the 60mm tubing usually used as an upgrade.

Rob.

I was just gonna use the 2 bolts to start with but was told the 3 bolt mount was the way to go ... can't see it making a huge difference tbh, but i done it for piece of mind.
I've never seen 3" boost pipes on a std LET before, should be ok ? it will have more lag than 51 or 60 mm pipes but wether it'll be noticable or not .. you'll just have to find out !!
Good luck with it all anyway

Rich

[Rob77]

I was just gonna use the 2 bolts to start with but was told the 3 bolt mount was the way to go ... can't see it making a huge difference tbh, but i done it for piece of mind.
I've never seen 3" boost pipes on a std LET before, should be ok ? it will have more lag than 51 or 60 mm pipes but wether it'll be noticable or not .. you'll just have to find out !!
Good luck with it all anyway

Rich

As said, I will be upgrading to a different turbo / 200sx manifold setup in the next couple of months, so hopefully the bigger pipework will pay off then!

Cheers for the heads up on the mount mate, Rob.

[Paul]

That the mount to gearbox, you are talking about 3 bolts there?

[Rob77]

Yes mate - indeed we are!

[Rob77]

Update!

Remade brackets for FMIC out of thicker alluminum strip, as was unhappy with thinner ones. Solid as a rock now.

Boost hoses all sorted and tightened up.

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000273.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000274.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000275.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000276.jpg

Grille just fits!

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000278.jpg

[Rob77]

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000279.jpg

Close up pictures of the mounts

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000281.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000282.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000283.jpg

[Rob77]

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000284.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000285.jpg

View of the hoses on the turbo:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000287.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000292.jpg

[ashtal]

nice work mate. Thought this plate went on the underside of the x member tho !
http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000069.jpg

[Rob77]

nice work mate. Thought this plate went on the underside of the x member tho !
http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000069.jpg

Interesting...

Didn't get any diagrams or instructions, so just fitted the plates where I thought they fitted best!

Not to worry!

[Rob77]

Bit more of an update...

Decided to make the front pannel removable, so chopped out a section of the old one, drilled holes for mounting the replacement pannel, then painted everything:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000329.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000330.jpg

Note section cut out for inlet hose in image below:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000331.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000332.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000333.jpg

New pannel painted and fitted: (Drilled out bonnet catch bits, hence all the holes!)

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000334.jpg

Little "L" shaped brackets to hold the bottom of the rad in place:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000339.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000336.jpg

Pretty good clearance for turbo, although was a bit annoyed that I damaged the new rad at some point without realising...

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000341.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000342.jpg

[Rob77]

Cooler back on:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000344.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000345.jpg

Sard regulator fitted:

http://img.photobucket.com/albums/v483/Rob77/P1000328.jpg

http://img.photobucket.com/albums/v483/Rob77/P1000327.jpg

http://img.photobucket.com/albums/v483/Rob77/P1000326.jpg

http://img.photobucket.com/albums/v483/Rob77/P1000325.jpg

Filter, AFM and hose fitted:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000346.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000347.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000348.jpg

[Paul]

Don't mean to clog up the thread here Rob, but for my gearbox mount not only have I used 3 holes where they usually go on Novas', but I have also welded a plate onto my mount, where the cally mount goes at the back, so iv got 4 bolts holding mount to box.

Heard a horror stroty of ripping gearbox casting in half! lol

Why does your passenger side mount sit so low compared to other ones I've seen, different mount from gearbox?

[Rob77]

And finally, grill and bumper back on:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000351.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000353.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000357.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000358.jpg

[Rob77]

Don't mean to clog up the thread here Rob, but for my gearbox mount not only have I used 3 holes where they usually go on Novas', but I have also welded a plate onto my mount, where the cally mount goes at the back, so iv got 4 bolts holding mount to box.

Heard a horror stroty of ripping gearbox casting in half! lol

Why does your passenger side mount sit so low compared to other ones I've seen, different mount from gearbox?

Not heard of castings being dominated before! Will be investigating the three bolt mount mate, but I'm sure that will be fine, a lot of cars run the 2 bolt mount on the gearbox like mine on the LET with no probs.

As regards the passenger mount, I don't know about it being low... It sits the same as most other Nova turbos I've seen, eg:

http://img.photobucket.com/albums/v483/Rob77/IMG_0790.jpg

[Paul]

Hmmm, It doelooks lower than mine is, mine has got a different mount plate that biolts to the gearbox though, maybe mines longer or somethign.

Rob, Did your F28 catch the lip on the arch?

[Rob77]

Hmmm, It doelooks lower than mine is, mine has got a different mount plate that biolts to the gearbox though, maybe mines longer or somethign.

Rob, Did your F28 catch the lip on the arch?

Nah the f28 JUST misses the arch by about 2mm or so.

Not got a picture though.

Rob.

[krobinson]

I've a late spec LET too mate, what alternator you running?

[Rob77]

I've a late spec LET too mate, what alternator you running?

Running the same alternator as my XE (even though the XE was the early belt type).

Just running the single V pulley on the crank, and used the alternator mount off the XE.

Rob.

[ste porter]

my old 2.0l had just the 2 bolt spacer plate and it sheared 1 bolt off level with the box and smashed a chunk out of the other when it went and i ended up on the side of a duel carrage way with my engine on the piss touching the floor snaped linkage and the other 2 rubber mounts riped due to the engine twisting it also poped my shafts out as it snaped and rounded the ends of my cv joints of as the diff was obviously still spining against the ends its not nice trust me i wont put one in now without welding the spacers 2 the mount and using the 3 bolt method not even 2.0l 8v ones

[Rob77]

my old 2.0l had just the 2 bolt spacer plate and it sheared 1 bolt off level with the box and smashed a chunk out of the other when it went and i ended up on the side of a duel carrage way with my engine on the piss touching the floor snaped linkage and the other 2 rubber mounts riped due to the engine twisting it also poped my shafts out as it snaped and rounded the ends of my cv joints of as the diff was obviously still spining against the ends its not nice trust me i wont put one in now without welding the spacers 2 the mount and using the 3 bolt method not even 2.0l 8v ones

:eek: Bloody hell mate that sounds terrible!

I think I'll be buying the three bolt mount kit!!!

[pickle]

those pictures really help a bone idle git like me. i bought a strengthening kit from harry hockley and the diagram that shows you how to put it in is poor. your car looks spot on, only wish id have stuck in at school to fund a car like that! lol

[Rob77]

those pictures really help a bone idle git like me. i bought a strengthening kit from harry hockley and the diagram that shows you how to put it in is poor. your car looks spot on, only wish id have stuck in at school to fund a car like that! lol

Glad to be of help!

[joff-turbo-nova]

my old 2.0l had just the 2 bolt spacer plate and it sheared 1 bolt off level with the box and smashed a chunk out of the other when it went and i ended up on the side of a duel carrage way with my engine on the piss touching the floor snaped linkage and the other 2 rubber mounts riped due to the engine twisting it also poped my shafts out as it snaped and rounded the ends of my cv joints of as the diff was obviously still spining against the ends its not nice trust me i wont put one in now without welding the spacers 2 the mount and using the 3 bolt method not even 2.0l 8v ones

If you want a belt and braces job on the rear mount try this :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/corsa20023.jpg

This is from a scandanavian 600bhp beast !

Joff

[Rob77]

Is that the white mk 1?

The one with the massive i/c?

[Rob77]

UPDATE TIME AGAIN!

The Nova is now on the road, as of Friday 16th March, when I insured and MOT'd it !!!

So the final steps; Saturday 10th March:

Received my top hat from Scooby's group buy on Migweb, (after an 8 month wait!!!), and when offering it up, it didn't clear the bonnet by a big amount!

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000499.jpg

Also the wiring for the inlet temp sensor didn't reach (and I broke the plug trying to make it reach! :mad: )

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000500.jpg

Hose off the ICV didn't reach or look easy to make reach either!!!

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000501.jpg

Quite a step in the throttle body as well...

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000503.jpg

Flange shape was interesting...

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000507.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000509.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000510.jpg

So decided to not bother with it, and sold it on to a lad on Mig with a Cav turbo that it would have a better chance of fitting on!

[Rob77]

Work started on the modification of the tie bars to accomodate the 50mm spacers at the front crossmember...

Normal section chopped off:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000512.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000514.jpg

New piece made up, that made the whole 50mm higher than the standard plate:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000513.jpg

[Rob77]

Another view of the plate (2mm thick mild steel)

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000521.jpg

We decided the plate should be thicker, so we cut 4 plates out, using a slightly less complex shape, and then welded two plates together, and welded them to the tie bar brackets:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000523.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000524.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000527.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000528.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000529.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000530.jpg

Very chuffed with the welding on these!!! :thumb:

[Rob77]

Tie bars and ally spacer blocks fitted:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000536.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000532.jpg

Lovely clean Wilwoods!

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000534.jpg

Note the spiggot rings I had machined up by a friend for the disks...

[Rob77]

Just for the record, I used 30mm square blocks for the wishbone side, and 50mm square blocks for the front.

(Obviously used 50mm longer bolts, and 30mm longer bolts respectively...)

[Rob77]

Next thing to think about was the top hat - as I didn't have a standard one, due to selling it earlier in the year...

So, we decided to have a go at knocking one up ourselves using some spare 3" ally pipe I had left over from the intercooler piping.

Pieces cut and insulating taped together for mocking up:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000515.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000516.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000517.jpg

A lot lower than the other tophat I had, and also pointed down towards my boost piping in the bay:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000520.jpg

Not bad flow:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000519.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000518.jpg

The flange that I cut out of 4mm thick ally, and a piece of Raleigh Max bar end chopped up for the pipe to the ICV!!! All ready to weld:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000554.jpg

[Rob77]

Dropped the bits off at a place near Just Nova's in Long Eaton that was recommended to me by a mate, and picked it up the next morning all welded, smoothed off inside, and ready to fit! (Bit faster than the 8 months I waited for the one off Mig!!!)

Fitted:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000558.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000559.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000560.jpg

(Note the inlet temp sensor that I tapped into the dump valve T piece after extending the wiring)

Finished engine bay:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000562.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000557.jpg

I started it up, after filling it up with oil, coolant, gearbox oil etc... And it started up instantly, straight away, no faffing about! I nearly wept with joy it all happened so easily! No tapping, smoke, or leaks! AMAZING!

[Rob77]

A few pictures of the car:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000537.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000541.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000544.jpg

Number plate fitted (in a crap place... Need to find a new location for that! Don't want a square plate though...)

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000566.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000568.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000558.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000559.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000560.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000562.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000557.jpg

[Rob77]

I bodged the Nova gear linkage back in after shortening the relevant piece. (Was planning on using a Corsa linkage direct to the box, but didn't get it sorted for the MOT - will be sorting that soon though.)

Can't get 6th gear, not sure why, but not too fussed as yet.

Bodged an exhaust together using the Cally downpipe, a Nova 1.3sr old system from Phil at Just Nova's (thanks again for that mate!), and a lot of jubilee clips!!!

It is gas tight though, so that's all that mattered for Mr. MOT tester!

Took it down for its MOT on the friday, and it passed no probs, all sounds as a pound! No advisaries or anything!

Was having a minor problem with the car though, had not wound the actuator on much, so was only running low boost, but when I was putting my foot flat, the engine was misfiring when it started coming on boost (about 9psi), but if I let off the throttle slightly it was fine.

After much stressing and fannying about on Mig, advise from Phil at JNC (ledgend!) pointed me towards the dissy cap and rotor arm, which turned out were totally dominated! Replaced them at Halfords for less than ?10 (on trade) and it was running like a charm!

So, obviously gave that car a good running about, (good lord LET Nova's are fast by the way!), and all was good, so I wound the actuator on 'till it read 1bar on the boost gauge, and it was ripping! (Needs a bloody LSD though!)

Unfortunately, it has developed a second problem which I still have not sorted as yet... On the way home from work I was giving the car a bit of stick, and it was pulling nicely to around 1bar of boost, really shifting.

But then when it was on boost pulling through 3rd, the power dropped, and it sounded alot raspier all of a sudden...

Now I thought it might have been a vac hose or boost hose popped off, so I took it home and left it until the morning when I could look at it in the light.

Checked all vac lines and boost hoses and they seem fine...

Driven the car since, to try and work out what is going on, and the engine runs fine (no missfires or stutters), but when I put my foot down, the normal turbo sound, sounds a lot harsher and raspier, and will only boost to about 0.2 bar (as apposed to the 1.0bar I was running previously)

Been told on Mig it sounds like the penny valve in the turbo has fallen off, hence the harsher sound, and no ability to build up boost, but haven't had the chance to properly inspect it as yet! Hopefully getting on to that tomorrow, so I will update when I know whats going on!

[Adam]

Looks very nice, the Ic looks quite cool now, seems to fit well.
Hopefully it wont cost much to sort the boost problems.

[rybo]

makes my baby xe look a bit of a waste of time but respect where its due here-impressive

[Rob77]

Cheers for the replies guys!

Yeh the intercooler does look a lot better now the car is back on the floor. I think the intercooler looked so big and obtrusive before, because the car was so high on blocks, meaning the intercooler was at almost eye level. (Well, not quite eye level... but you get the point!)

Worst comes to worst and the penny valve has died, I can pick up a decent condition standard turbo for less than ?100, or maybe go t34 or something similar...

[Rob77]

makes my baby xe look a bit of a waste of time...

Not at all mate - I've had a look at your project thread; your shell looks split mint, and those small XE's can put a decent amount of power out, and more importantly, will handle like a dream!!!

:thumb:

[lee coley]

some nice pipe work there mate that top hat looks cock on!

[Rob77]

some nice pipe work there mate that top hat looks cock on!

Cheers dude!

:thumb:

[R1CH]

Gotta agree with Yoza there, that TopHat looks bang on !! That one from Scooby on Mig looks shocking for ?100 !! i was thinking of buying one but decided it couldn't to be to hard to make yourself, was gonna some plate & a 3" bend this weekend but seeing your i might just get a piece of straight 3" and get cutting !!
Good work fella
:thumb:

[Philsutton]

well have to say its looking good, welcome to owning a c20let though. When they run right they are spot on but most the time you want to kill it. Hope you get this lastest bit of gayness sorted. Like i said before it does sound like a wastegate related problem.

Also im still waiting for my turbo to arrive, but I have got myself a well bo dump valve as i need one lol

[Adam]

Top work on that top hat, should get a few made up and sell them....


Whats your insurance like with the LET fitted?

[Rob77]

Gotta agree with Yoza there, that TopHat looks bang on !! That one from Scooby on Mig looks shocking for ?100 !! i was thinking of buying one but decided it couldn't to be to hard to make yourself, was gonna some plate & a 3" bend this weekend but seeing your i might just get a piece of straight 3" and get cutting !!
Good work fella
:thumb:

Cheers mate - was pretty quick and easy to make!


well have to say its looking good, welcome to owning a c20let though. When they run right they are spot on but most the time you want to kill it. Hope you get this lastest bit of gayness sorted. Like i said before it does sound like a wastegate related problem.

Also im still waiting for my turbo to arrive, but I have got myself a well bo dump valve as i need one lol

You won't believe this Phil, but I drove the car tonight to get to a wedding reception (was my only way of getting there), and on the drive home, the car just suddenly fixed itself! What a ledgend! I was tootling along down a country lane, and gave it a bit of stick, and as usual it was only boosting to about 0.2 bar, making that raspy noise as I described, and then suddenly, it kind of stuttered (very briefly), then went ape sh!t up to just over 1 bar, pulling like a bloody train! Was spot on then all the way home (about a half an hour drive)! Heres hoping it remains like this from now on!

The only explanation I have to the resoultion of this problem, was that something had got stuck open (wastegate / penny valve / something else that would mean all boost was lost down the exhaust), and while driving home tonight it un-jammed itself and is now working properly!

Also, whats this news of a turbo? What you gone for in the end? And dump valve??? :eek: Thats CRAZY talk for you! What chav valve you gone for then?

As said, looking forward to seeing your car moving again! Every time I see you its just died and I've missed it running right once more! Last time I saw it moving was PV last year!!!


Top work on that top hat, should get a few made up and sell them....

Cheers mate - am actually thinking about doing that, also with the tie bars as well...

[Rob77]

Whats your insurance like with the LET fitted?

Insurance is ?900 fully comp for the year. 1 year NCB and I'm 22.

Pretty damn good if you ask me!

Its with a company called Frizzell (spelling), they are a subdivision of Liverpool Victoria. (08456097191)

[Adam]

Thats a f**king bargain!

I got a quote, ?2200
Driving for 3yrs, with 3yrs ncb!

[draper]

?900 is a absolute bargain

[Rob77]

I have been driving for 5 years though... But yeh, 1 years NCB, with a Nova LET (all mods declared - totally legit), for ?900 is pretty awesome!

A mate of mine told me about the company a while back (his whole family use then - and I can see why!)

Rob.

[Adam]

I used to be with LV(Frizzel) on my old car
and they told me they wouldn't cover mods,Lol.

They mustn't have liked me or something lol

[Rob77]

I used to be with LV(Frizzel) on my old car
and they told me they wouldn't cover mods,Lol.

They mustn't have liked me or something lol

Thats pretty weird! :wtf:

[Adam]

They wouldn't cover a set of 16s on my astra,Lol.
Perhaps it was because i was 17/18

[Rob77]

Maybe... :confused:

[Adam]

It seems LV have changed quite a bit since i was with them.
The website is different, and can cover mods online etc.

[Rob77]

Update time...

Been a bit slack, with uni finally nearing the end (dissertation etc)...

Racetech boost gauge fitted:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000751.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000762.jpg

Lightweight pot type flywheel (6kg) which allows more clutch choice:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000848.jpg

New Techniclutch paddle clutch and pressure plate, all beautiful and red!

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000851.jpg

Clutch is rated to 490bhp, and is the same one Phil Sutton is using.

New Racetech oil pressure and oil temp gauge:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000852.jpg

[nova ian]

I like the guages, very minimal and somewhat different. Like it! Fantastic build mate.

Off topic, just checked out yuor myspace, Im liking that too! Im quite partial to a bit of D&B!!:thumb:

Keep up the good work on both the nova and music production.

Cheers

Ian

[Rob77]

Cheers mate!

[LJH]

get a number plate sticker on the very edge of the bonnet, it'll look bad ass

[S.Nelson]

Awesome Build m8 Fantastic :cool: :D Hopefully going to start on mine soon

[joff-turbo-nova]

Great work - I'm using the same Racetech guages - don't trust the electrical types!!!

Joff

[Rob77]

get a number plate sticker on the very edge of the bonnet, it'll look bad ass

Hmm, worth a try. Also want to try a bike sized square plate offset at the front (but I'm 99% that will look a bit gay).


Awesome Build m8 Fantastic :cool: :D Hopefully going to start on mine soon

Thanks dude! Make sure you get a progress thread going too!


Great work - I'm using the same Racetech guages - don't trust the electrical types!!!

Joff

Yeh, I did have a load of Splitfire electrical gauges - but decided to sell them, and use these... Seem to have a lot of good reviews!

[Rob77]

Update time again!

Took the engine and box out on Friday to fit the new clutch and flywheel shown a few posts above.

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000875.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000876.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000877.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000878.jpg

As luck would have it, I popped down to Just Nova's to get a new inner CV joint for my 22 spline shafts, and they had a new Quaife ATB diff on the shelf for an f20 gearbox for ?500...

I figured, while the gearbox was out, this was an oppertunity not to miss! Only problem was, I had got no money!

After chatting with Phil, he said they needed an XE engine for a Corsa that had just come in for a conversion, to which I replied "I've got my old Coscast XE sat at home from my Nova!" I wanted around ?500 for it, so after some haggling with Paul I ended up swapping my XE and a bit of cash for the ATB diff!!! AWESOME!

I dropped the XE off later on (about 11pm!), along with a random f20 box I had knocking about. I also took my f28 along, so I could get a few pointers off Paul for the diff fitting. Split the f28 there, and swapped the crown wheels on the diffs.

Pics below of how the box looked after we got home from JNC late Fri night:

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000880.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000881.jpg
http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000882.jpg

http://img.photobucket.com/albums/v483/Rob77/Nova%20LET/P1000883.jpg

The following morning (Sat), we set about removing the lip from the f28 gearbox housing, which we did using a few files and a lot of swearing!

The bearing cover thingy from the f20 box then just slid in, clamping the diff in place.

The main pain of this job was getting the box casing back on again, as the bearings all kept moving out of line, but after a few angry hours of jiggling around, it finally dropped on.

The clutch and fly were then fitted, and the box bolted back on.

The engine and box were then chucked back in, and everything was reconnected.

RESULT!

No more pics though, as camera battery died!

Many thanks to Phil and Paul at JNC, for the help and the swapping of bits!

Also many thanks to my mate Pog who helped out (as always)...

Car has been transformed once again, with no torque steer now, and a hell of a lot less wheelspin!

Clutch is loads better, and doesn't slip now which is nice!

Thats all for now guys!

Rob.

[R1CH]

Jobs on !!
All sorted for PV ?

:thumb:

[draper]

nice work on the diff :thumb:

if id of known JNC were willing to pay silly money for XEs id flog em mine ;) lol

[Adam]

Top work

[Rob77]

Jobs on !!
All sorted for PV ?

:thumb:

Yeh pretty much! Just hoping to get some 888's - but that is pretty unlikely!

Cheers for all positive comments!

[novaboyopr]

alrite mate. i was talking to you a pv black nova dma up the side. can u do anymore of them top hats? price? oh and my bro wants to know where you got your mirrors from. pm me or something.

[BigStan]

Just read through it all, looks like a top job mate lovely car !

[twin40s]

i want a turbo

[maccas]

like the bultaco trial bike haven't seen one of those in a while! is it a 325 or a 250? car is looking spot on

maccas

[Rob77]

like the bultaco trial bike haven't seen one of those in a while! is it a 325 or a 250? car is looking spot on

maccas

Cheers!

Your the second person whos mentioned it now!

It is a 325cc.

Lovely bike!

You ride?

[maccas]

got into bikes when i was 12 n had them pretty much till now, but as soon as i got a car they sort of got side tracked, i so wish i had done my 33bhp test at 17 but just didnt have the money, and now with being at uni i don't have the time, i'm fanatical about two strokes though, they are awesome always wanted a yamaha tzr250 or a suzuki rgv250 they are stupidly fast!! had a few 70's trail bikes like dt175 twin shock (wish i still had it now they are worth a fortune) dt175mx kawasaki ke125 CZ175 trail bike(what a heap of s**t) had about 27 bikes in total lol do you get chance to ride it much? i bet it pulls well low down doesn't it?

maccas

[Rickyb]

nice work pal reali enjoyed readin not a big fan of the big i/c but its still nice :thumb:

[Rob77]

Yeh the Bultaco has got enough low end power and torque to pull you up just about anything!

I am in a similar situation to you mate, but have just finished uni, so may be thinking about my bike test in the near future!

A mate of mine had a TZR250 - was pretty nippy!

[cheshiresport]

Thats awesome mate

[Rob77]

Video now on YouTube from PVS 2007...

http://www.youtube.com/watch?v=JwZqk0ZWhto

[Adam]

Is this your car mate? On the right
http://smg.photobucket.com/albums/v86/Nova-crew/?action=view&current=Paul12.flv

[Rob77]

It is indeed!

Is there anyway you can send the video to me?

nottscruiser@hotmail.com is my email / msn address...

[Adam]

Email sent, file is about 5meg so may take a few mins :)

[Rob77]

Thanks a lot mate!

(Apologies for PM-ing you as well!)

Rob.

[Adam]

:thumb:

[ThomasD]

Very great Nova!!!

Greats from Germany!!

[hybridturbo]

What wheels are on now?

[Rob77]

I have bought some 20" chrome wheels that I'm going to make fit....

(Not really - some 15" Cesaro's!)

[Adam]

Any pics of the new rims on?
Good choice btw,Lol.

[bonelorry]

top car mate!

if you go for 20" chromes though make sure you get some spinners too lol

[Rob77]

This car is now being broken!

See for sale thread!

[squealer]

mint looking lad