Peesters Little Project: My return to novaism. (Lots of pics)

[peester]

oh repeaters - mr john h..
im just going to leave them lol.. wings are mint so no reason to change.. but if i do ever go kevlar or f/g front wings ill pop original type side rep's back on, only clear..

[John]

Astra G side repeaters were all the rage 10 years ago!

[peester]

:) they look fine anyway, nice and low down is good.

[John]

:) they look fine anyway, nice and low down is good.

Yeah i thought they looked a little lower too. Just personal taste i suppose. :)

[scott.parker]

Yeah i thought they looked a little lower too. Just personal taste i suppose. :)

lol i did this to my old GSi when i got it resprayed..

http://www.pngclub.com/images/car_images/1970big4.jpg

They was some rank LED jobs, when LED was new on the scene! lol :thumb:

Look forward to an update mate.

Scott

[peester]

*Update.
Still not much development, yet lol, - just been accumilating the parts for the next, final (hopefully) stage of progression, over winter. As mentioned in last update..
http://img.photobucket.com/albums/v11/peester/Photo0467.jpg
Moved the car into the new lockup, and all my stuff.. First job is to get a decent enough internal gear linkage arrangement.
Ive missed out of a few quaife group-a linkage's over the last few weeks ,i just cant stretch to the prices theyre fetching at the mo.. So instead, ill hopefully get a similar result by bodging a trusty cav/calibra internal shifter onto a mk1 Astra linkage bar :-s
http://img.photobucket.com/albums/v11/peester/gear003.jpg
Ive found a cav shifter just waiting to seller to strip the car then i can pay and itll get posted..
If this manages to get all 5 gears quickly and easily accessible then im taking the car to retropower to get the sump modified and fitted and the BTB manifold will get modified and fitted, now that the linkage is out of the way of the exhaust tunnel..
Then the car will actually be at the stage it was supposed to be at for the 2010 summer/show season lol..
Twin port Bailey header tank (always wanted one of these anyway) but with the modified LET twin port-ness itll tidy up the coolant piping under the bonnet nicely, really chuffed i found this.
http://img.photobucket.com/albums/v11/peester/Photo0421.jpg
Whilst im taking the cooling system apart ill drop a nice new alloy radiator from TX in too - look to bring the temp's down a bit as the one on the car looks fair few years old..
Driving it is egging me on to get it finished one way or another, if these afore mentioned bodgery doesnt work then ill just have to hold out for a quaife jobby after all lol
More again soon.

[vaughanmc]

Looks very well on they SR steelies :)

[John]

Dave are you on rear coilies now?

[peester]

Dave are you on rear coilies now?

nah 4" pig tails.. still with your bilstein shocks. Ive got a few rear springs.. think those are 225lbs, will prob go find and fit slightly higher poundage springs, it rides nice now believe it or not but when throwing it round theyll prob roll too much..we'll see..

thanks vaughan, i agree.. its the tyres that help (175/50x14) with the look n stance a bit too..

[John]

nah 4" pig tails.. still with your bilstein shocks. Ive got a few rear springs.. think those are 225lbs, will prob go find and fit slightly higher poundage springs, it rides nice now believe it or not but when throwing it round theyll prob roll too much..we'll see..

thanks vaughan, i agree.. its the tyres that help (175/50x14) with the look n stance a bit too..

Really? that stance is awesome!

[peester]

Really? that stance is awesome!

cheers john, thats how i like to roll lol :thumb:

[peester]

*Update.
Despite still no joy with the astra mk1 shifter/linkage i bought all those weeks ago, i need an internal shifter doing for my exhaust/ground clearance issue anyway so with the arrival of cav shifter spurred me into doing something i made a start on that today.
I have some questions too so thought ide put up what ive done, so far.
So, old shifter out.
http://img.photobucket.com/albums/v11/peester/Photo0486.jpg
Made a start on the floor/body modification.
http://img.photobucket.com/albums/v11/peester/Photo0494.jpg
http://img.photobucket.com/albums/v11/peester/Photo0498.jpg
Im cutting what will end up being, a neat narrow gap through the carpet-support bit that widens out a bit at the top where then the usual elongated hole in floor as per instructions..
http://img.photobucket.com/albums/v11/peester/intshmod.jpg
So the couple of questions..
How do you remove the gear shifter surround bit that the old shifter bolted to; just grind away or does it have x4 spot welds that need drilling out..? -or both..? like in this pic from ad's thread..
http://img.photobucket.com/albums/v11/peester/027ecdd9.jpg
Finally; here is my cav shifter and where i shall make the cut; to get rid of the kink (?)
http://img.photobucket.com/albums/v11/peester/cavsshift.jpg
At this stage; with me being clueless with not seeing the astra mk1 item yet il then hold fire and see what might be possible. If i stick with the 'S' nova-linakge ill then also need to shorten this cav shifter it by a further 3 inches is it, with another cut..?
Ill just worry about that as n when i think lol.
Hopefully the astra mk1 bit will show up next week.

[draper]

good work mr peester

is the engine running properly now then ? really interested to see the results

[peester]

cheers draper the engine has been running ok all summer, but it isnt mapped yet. All i have planned are the exhaust manifold with lambda boss, an alloy rad and sump swap then ive yet to buy the cat-cams and piper verniers, then off the get it mapped properly.

[draper]

any estimated figures (sorry if youve said it a few times but i cant be bothered trawling through your thread lol)

[peester]

see here:
http://www.migweb.co.uk/forums/projects-restorations/404120-my-1-8-z18xe-corsa-c-jenvey-throttle-bodies-5.html#post4169694
im hoping for bit more torque than mike's tho lol

[Adam]

Dave, its held with spot welds.

Basically, you need the make the shifter completely straight.
Be aware tho, that the shifter in your pic wont fit a nova linkage, because its got the wrong type of fitting on the end. The nova one has a clamp fitting on the shifter, the clamp bit is on the linkage itself on a cav so the shifter is just a solid rod at the end.

[AlexW]

Get a cav (i belive there the same?), or a corsa gear linkage end and you can replace the crappy standard bush that nova linkages suffer from, and new bushs for the corsa bit are about £7 for the pair iirc.

[peester]

ah cooly; will be drilling them out tommorow then, wicked..
thanks ad - yeah i noticed the ends are different; as said that'll only be an issue if i dont use the astra mk1 bit and keep the nova 'S' linkage..

[Adam]

Astra mk1 bit?
Tell me more

[peester]

Cant say much ad, ive not received it in the post yet.. but im hoping to use this somehow - it rids of the nova 'S' linkage bit - goes direct to turret.
http://img.photobucket.com/albums/v11/peester/gear003.jpg
http://img.photobucket.com/albums/v11/peester/gear006.jpg
http://img.photobucket.com/albums/v11/peester/gear004.jpg

[Adam]

Oh right, looks like it would need a few mods it get it to fit.
Not heard of it before though.

[opelbuck2000]

some nice work there mate.. keep it up

[peester]

Oh right, looks like it would need a few mods it get it to fit.
Not heard of it before though.

Yeah it might not work lol.. Dont know if ill use all/some/any of it.. gonna try tho.

thanks guys

[Mazz]

Throw a standard one and enjoy it! at least you will be able to get all 5 gears then too ;)

[peester]

Managed to remove the surround part today, but it took me most of the afternoon lol
http://img.photobucket.com/albums/v11/peester/Photo0505.jpg
http://img.photobucket.com/albums/v11/peester/Photo0507.jpg
Hopefully make swifter progress next weekend.

[peester]

*Update,bit overdue :-s
Imcurrently sat bored waiting for a mate to come get me and go finish repairing my vectra (cambelt went about a month ago now) ive spent the last few weeks without a car i can use, despite owning 2 lol. Not to mentioned remainder of nova budget now spent on fixing the daily hack. L
Ive had a few peeps asking how im getting on with the nova, why no updates in ages so ill try bring things up to speed..
Continuing from the last update in mid October, the only definite decision ide made with this shifter/linkage gig was that it was going to be internal, so ide made a start and cracked on with chopping and hacking at the floor of the car; doingthe usual prep work as we’ve all seen time again.
However,i was hoping to end up using this astra mk1 linkage bar, instead of keeping that so-far-cant get-on-with-it quickshift bracket/rosejoint o.e –sytle setup.
http://img.photobucket.com/albums/v11/peester/IMG00135-20110213-1135.jpg
This meant when i got to the part where you drill through the middle of the floor for the elongated/slotted hole, im supposed to be drilling in the passengers footwell instead; like many quaife shifter/linkage users have done.
Anyway i spent weeks trying to work out how best to do this, and bar actually welding the plate over the old shifter hole; ide achieved this mess all by myself lol.
Cut carpet support, offered plate over hole:
http://img.photobucket.com/albums/v11/peester/Photo0520.jpg
Welded plate over..
http://img.photobucket.com/albums/v11/peester/Photo0563.jpg
..from underneath:
http://img.photobucket.com/albums/v11/peester/Photo0561.jpg
Made hole in bulkhead. Hope its right lol
http://img.photobucket.com/albums/v11/peester/IMG00018-20101212-1435.jpg
Offered Astra linkage bar up through the hole, connected it loosely to gearbox..
http://img.photobucket.com/albums/v11/peester/IMG00068-20101228-1212.jpg
http://img.photobucket.com/albums/v11/peester/IMG00072-20101228-1214.jpg
Result was the astra bar is a tad too long. Needed shortning. Plus the floor , to mount it to; is too low down or the steering rack gets in the way. So when attaching it to the box selector – the whole bar sat up off the floor as in the above pic. To get it to sit on the floor of the car; it needed disconnecting from the box; so was at the wrong angle.
http://img.photobucket.com/albums/v11/peester/IMG00075-20101228-1219.jpg
But i was hopeful it would work and my guess work seems close enough. But In the end, for me without decent fabrication skills and tools; this was as far as i got. Went about getting it booked in for someone to do for me. Ended up being in 4 months time(!)

[peester]

In the meantime i tried to get on with other jobs, fitted a vent hole in the firewall, behind the ITB’s to draw colder air through the scuttle panel area.Plus i thought it may extract some heat and more noiize lol..

http://img.photobucket.com/albums/v11/peester/Photo0572.jpg

http://img.photobucket.com/albums/v11/peester/Photo0580.jpg

http://img.photobucket.com/albums/v11/peester/Photo0583.jpg

http://img.photobucket.com/albums/v11/peester/Photo0584.jpg



I also de-rusted, partly-cleaned and painted the battery tray area; and fitted a tray as ide never had one.

http://img.photobucket.com/albums/v11/peester/IMG00227-20110306-1648.jpg

http://img.photobucket.com/albums/v11/peester/IMG00231-20110311-1459.jpg

Good enough. Also at that same time, ide been umming and arring about with what, how and where to replace my ageing oasis bottle catch tank, making templates n everything!

http://img.photobucket.com/albums/v11/peester/IMG00138-20110213-1530.jpg

[peester]

Then i turned my attention to the cooling side of things.
http://img.photobucket.com/albums/v11/peester/Photo0190-1.jpg
I wanted to replace this ugly looking 2into1return that ive put up with for ages and we’de all been about TX alloy rads onthe forums alot at the time. So the chain of events with that:
Took old header and pipes out:
http://img.photobucket.com/albums/v11/peester/IMG00144-20110220-1446.jpg
Offered new bailey header up:
http://img.photobucket.com/albums/v11/peester/IMG00156-20110220-1547.jpg
New rad vs old:
http://img.photobucket.com/albums/v11/peester/IMG00160-20110221-1706.jpg
New rad fitted:
http://img.photobucket.com/albums/v11/peester/IMG00165-20110228-1439.jpg
Fitted up new pipes arrangement:
http://img.photobucket.com/albums/v11/peester/IMG00169-20110228-1551.jpg
http://img.photobucket.com/albums/v11/peester/IMG00174-20110302-1738.jpg
New fan, 11” Spal, suction; onto brackets:
http://img.photobucket.com/albums/v11/peester/IMG00206-20110304-1648.jpg
During fitting:
http://img.photobucket.com/albums/v11/peester/IMG00208-20110304-1724.jpg
http://img.photobucket.com/albums/v11/peester/IMG00209-20110304-1724.jpg
Finished:
http://img.photobucket.com/albums/v11/peester/IMG00225-20110306-1647.jpg
Fan brackets a bit visible through grille/panel gaps.. oh well:
http://img.photobucket.com/albums/v11/peester/IMG00250-20110313-1316.jpg
However,as seen in technical rooms; have experienced some leakage from the radweld/joins:
http://img.photobucket.com/albums/v11/peester/IMG00261-20110313-1551.jpg

[peester]

So with the date of linkage fabricating now looming, i thought it would be an ideal time to get the ground clearance issue i have sorted. As hopefully these parts could get fitted at the same time. So i got them prepared. For this i took the (shallower than existing z18xe) x16xe sump i sourced:

http://img.photobucket.com/albums/v11/peester/IMG00086-20110115-1032.jpg

And got it slightly modified, just had the deepest part trimmed back a tad; to be sure lol:

http://img.photobucket.com/albums/v11/peester/IMG00108-20110207-1703.jpg

Then i needed to get my BTB manifold re-flanged, as again theyre for x16xe only; so i managed to get a piper z18xe flange on its own, got the swap done. A lambda hole and boss was drilled, fitted and bunged. I then heat wrapped it; all in a bit of a last minute rush-photos missing would you believe.

I then prepped the car for the trip to fabricators; stripping out the interior,raising ride height etc.

http://img.photobucket.com/albums/v11/peester/IMG00253-20110313-1317.jpg



Then it went off to retropower.

http://i77.photobucket.com/albums/j42/doubledecka/Z18XE_Nova/2011_04110012.jpg

[peester]

In a nutshell they had a pig of a time with the car; the shifter part of the work not really causing any problems, perhaps helped by my earlier prep work lol..?
They removed the carpet support completely, nicely, painted the floor and fitted what can only be described as a pretty professional looking quaife/race carstyle shifter using the astra linkage part i supplied. And using the hole imade; as mentioned earlier and as expected – raising the floor mounting so itcleared the steering rack.
During fitting:
Cut out support, raising floor, enlarged my original hole:
http://img.photobucket.com/albums/v11/peester/IMG_4774.jpg
Fitted astra linkage bar, custom shifter:
http://img.photobucket.com/albums/v11/peester/IMG_6460.jpg
Finished:
http://img.photobucket.com/albums/v11/peester/2011_04110010.jpg
http://img.photobucket.com/albums/v11/peester/2011_04110011.jpg
Bolted to supplied connector at selector:
http://img.photobucket.com/albums/v11/peester/IMG00274-20110421-2000.jpg
http://img.photobucket.com/albums/v11/peester/2011_04110009.jpg
Main thing is it works, nice and direct feeling – as it of course goes straight to the box selector itself.
Still a little to get used to it though.
So to the trouble-some bits. They struggled with the sump and manifold.
The sump first, successful with the pickup pipe (was shortened 20mm) they couldn’t work out how to avoid the top scraper baffle coming into contact with the crank counterweights. So in the end they just removed the top baffle, further modifying the other baffles so it all fit on. Seems the 1.6 sump is a very tricky to job to do to the 1.8; on top of that they did it still with engine insitu, in the ‘bay, overhead :-s
Then the manifold: basically with the new flange being fitted elsewhere, with no engine/template as a reference – it naturally got fitted a few mm ‘out’ so they needed to find those few ‘mm’ here n there; bodywork and amongst other jiggery pokery. Also took them a few attempts to get it on.
The end result though is a great deal more ground clearance. Not to mention i now have a better 4-2-1 design manifold thats 2.5” bore; they had to cone down to the 2” magnex system the car has so a bigger exhaust is on the cards one day. Also the car is now lambda-ready for mapping.
http://img.photobucket.com/albums/v11/peester/SP_A1650-1.jpg

Retropower were going to MOT and TAX the car for me but the old rarely used ATE capliers on the car had seized. To keep costs down and not waste anymore of they’re time i got the car recovered back again, and after one or two hiccups (again as mentioned in technical thread of recent) with sourcing some used actual 256mm ATE callipers. Was incorrectly send smaller ones; ended up with a right plie of callipers now lol
http://img.photobucket.com/albums/v11/peester/IMG00296-20110507-1514.jpg
Eventually won some off ebay for £1, collected and theyre correct, in good nick; but not yellow.. yet lol. Fitted them anyway, just to be able to get the car driven round nearby, for the first time in almost a year :-s Which of course was great fun.
Im now left with fuelling to sort. A basic mapping session. MOT/TAX. Then fit these newcam cams and verniers. Then one final full map session.
Oh also one or two styling tweeks on the cards.
However,i am also moving out of parents home again, into my own flat soon – and as a co-incidence my mate has done too and in addition is getting married this year;so with that in mind we’ve now moved out of the unit we’ve been in, back into cheap poxy ex. Council garages.. Feel like im 21 again lol. Kind of. So for the time being we have lost the space and excuses (lol) to do much of this remaining work ourselves (these garages have no power, no light). Hopefully the car will be at least legal for PV.

[Cle]

Really like this car :) engine bay really is a work of art :thumb:

[Mike]

Really liking that shifter arrangement! Pretty damn cool idea that!

[mk1nova_rich]

Top work on the shifter mate :thumb:

[peester]

well, thanks lol but i cant take much of the credit at all - barely did any of the work; was all them @ retropower.

[Balley]

Facking amazing work!

[Connor]

ahh that shifter arrangement is ace, plus that dash is nom nom nom nom :wisewood:

[Iain]

They've done an awesome job of that! You had blue carpets in it before didn't you, are you going to attempt to keep those somehow?

[peester]

thanks for the replies; it is a relief with the end result, as it was a bit unknown what alternative there is to the o.e style linkage and the full blown quaife stuff.
But tbh ide seen a few astra mk1 setups fitted into novas and corsas so..

Iain, the carpets and seats are actually back in now. The under carpet sound proofing was easy to just cut around it all, but i was a bit more reserved with the carpet - all ive done for now is cut down the joins that normally live under the console/around the old gear stick handbrake area into two then tucked the excess under itself, if that makes sense. Its not super tidy but for now it will do; ill no doubt return to that issue in time and work something out. Probably just take my time cutting it around that new shifter setup.

[Mazz]

wow - Retro have really worked their magic, that shifter looks ruddy awesome, very hard-core DTM styleeee!!

Gonna have to come over and have a nose soon!

[Adam]

Is/Was there anything wrong with your old rad????

That shifter setup looks fooking awesome :cool:
I want a look at that because looking at the pics its hard see how it works/how theyve down it. The bottom is fixed to the floor? (or is it the angle of the pic?)
I take it your gears are in the right place? (standard linkage flips the shifter movement at the gearbox end)

[Iain]

Standard linkage flips the shifter movement at the gearbox end)

Standard Nova/Cav shifter pivots at the bottom doesn't it, this looks like it pivots in the middle and the bottom is attached to the shifter rod, fixing the issue of up/down gear selection correctness

[Adam]

Yeah that would explain things.

Yeah the "S" on the standard linkage "flips" the shifter movement.

[simonm]

that is well cool love that shifter say it makes it nice and direct

[peester]

Thanks again, for the replies.
The alloy radiator was just for peace of mind really; existing one was old, though didnt appear to be leaking - but i have been hoping for lower running temps. Same goes for the fan- theres about 4 or 5 blades on the old GM one; this spal has 12 or 13 i think.
The astra linkage bar and shifter is a more simple system in my opinion to understand and get on with, that the o.e nova S bracket.. it was just arkward to install internally, in a nova- as its actually externally fitted to astra mk1 and some mk2's. So a second 'floor'/mounting needs making. I did for ease, choose a mk1 astra GTE shifter assembly as they have the 5 speed, 1st for reverse identical layout. Doesnt make any difference of course that the GTE used a big block engine and 'box. Forgot to add the only difference, is the retropower shifter design means pull the whole thing up, and over for reverse..

[craig green]

Nice update, the ground clearance issue well sorted.

[MK999]

what size tyres are on that? As they look spot on for 14's!

[krobinson]

Love the shifter! Are you going to billing?

[peester]

Tyres on the steelies are 175/50x14. Am going billing yes, pv hopefully too..

[scott.parker]

Dave thats looking amazing mate! didn't expect that extrema shifter Assembly! mental... looks top stuff mate, must have a good look at it over the year etc.

And i was going to ask the same on them sr steels, must get some of them tyres for mine and plonk them on the mk1!

Let us know how you get on a Dave's.

Scott

[burgo]

thats some serious progress, look forward to having a poke around it

[peester]

*Wee Update..
Crickey, been nearly a month again already.. :-o
Not much to add yet really, as ive been mainly planning/sorting stuff for getting the car complete.
Pic missing from last update was that the interior went back into the car, prepping it slowly for MOT...
http://img.photobucket.com/albums/v11/peester/IMG00370-20110527-1635.jpg
http://img.photobucket.com/albums/v11/peester/IMG00380-20110527-1646.jpg
Been accumilating parts (over last few years tbh!) to sort the fuelling setup..
http://img.photobucket.com/albums/v11/peester/IMG00395-20110606-1941.jpg
http://img.photobucket.com/albums/v11/peester/IMG00359-20110524-2020.jpg

Because im having these parts fitted for me, by the place thats mapping the car on this occasion, this sorting/planning im on about is laying out/arranging the parts to make sure it'll all go together successfully.
Ive had many a question along the way though lol; like reguarding the pump ; is it possible its spec./ delivery may not suit my application..? Could it be too powerful..? Can such a thing be the case? lol
Anyway, ultimately itll speed things up as with no lockup anymore or bottles of enthusiasm left - plus the mapper being based there too so it sounds a nice easy drive in drive out gig.

Lastly for now i MOT'd it on saturday, was good to drive it about a bit again- but the need for mapping is too great to ignore and enjoy the car properly lol. So just some tax to sort then once the planning mentioned above all agrees i shall book it in. Next week or 2 hopefully.

In the meantime ill have to go PV in the vectra again lol.

[scott.parker]

Looking good mate..

So come on, where you planning on getting the work done/mapped?

Scott

[peester]

It is looking like going to MEK. Dave says the chaps next door can do the fuel pipe work. Then he will map it. Itll need trailering as its not exactly down the road, but its not too far away.

[John]

shifter looks awesome dave! It's really moving on now! :)

[scott.parker]

Good choice mate, you wont regret it.

Scott

[MARTIN KELSON]

Your on MBE management aren't you Dave.
Thinking of taking mine to Mikeanics in Congleton I think they are.
It's who Toovey uses for rollers & who SBD recommend for our area.
Thinking of booking mine in for next few weeks.

[peester]

Yes MBE and yeah have heard of them, wasnt aware of such a recommendation though..
You just looking for tweeks to yours then, since the dyno..?

If i have any jip with the MEK gig, then at least theres a more than useful alternative..

[MARTIN KELSON]

Yea just a few tweaks.
Seems to be running fine but when I was at Toovey's before it came of the road last year he advised I get it on the rollers now it's installed & on my exhausts etc just for the final settings.
Should only need a couple of runs as it wont be far out.
Who & where is this one your off too?

[peester]

Ah cool. MEK; best bet is to see here and here http://www.pngclub.com/forum/showpost.php?p=1837655&postcount=760
http://www.mekmotorsport.co.uk/home.html
On this occasion its just to get the car running right; 1st time mapping.
I was going to use tracknroad in rainham; as theyve done all 3 of the converted z18xe's that i know about. However ill probably go there for the second, more proper map; once the cams and verniers and bigger exhaust system has been fitted and a few miles on the clock first.

[Adam]

You cant really have a "over spec'd" fuel pump tbh.
The regulator will just control it to what you need.

Heard good things about Mikeanics, guy seemed sound when i last went there. Proper tiny place though,Lol.

[Mazz]

My Cav killed his rollers!

[Adam]

This is true lol lol

It is a pretty old skool place tbh

[peester]

yeah kinda what i thought with the pump then; just still getting bits together, prepping it for the get-it-running-right mapping session.
Ive no doubt come end of summer, with the cams and exhaust fitted ill be going to track n road for the final 'power' map.

[peester]

*Minor update..
In preparation for mapping i wanted to rid of this naff bodged alternator mount
http://img.photobucket.com/albums/v11/peester/IMG00403-20110611-1349.jpg
..and in turn discovered why a little slack may have started to creep back in:
http://img.photobucket.com/albums/v11/peester/IMG00415-20110615-1528.jpg
Bolt wasnt quite in the nyloc bit..
Sorted a longer bolt no problem, then went about mocking up a better neater top bracket..
http://img.photobucket.com/albums/v11/peester/IMG00439-20110617-1532.jpg
Then cut it out of 40x20x2 box section, ready to be welded:
http://img.photobucket.com/albums/v11/peester/IMG00451-20110622-2030.jpg
Fitted a smaller, neater catch tank..
http://img.photobucket.com/albums/v11/peester/IMG00446-20110619-1450.jpg
..But i still dont like it lol. It'll stay for now - its secure, fairly subtle.
And lastly for now; just kept accumilating parts for the fuel system upgrade:
http://img.photobucket.com/albums/v11/peester/IMG00453-20110624-1845.jpg
Theres still a couple of meters of hose im waiting to be delivered and a connector or two.
With those, and the alternator bracket made, fitted and all going well ill take it for mapping. Hopefully next week or so, prob after billing lol :-(

[Mieran]

that shifter is pimp as fook :cool:

[Mazz]

When are you going going to drive and enjoy it Dave!!?

[peester]

when its built chris

[Mazz]

Can't be far away now though

[peester]

nah nearly there - as the updates say - its just getting these fuelling bits then theyre being fitted at the mapping place, so fitting and mapping done in one go. Its taxed and mot'd now so if all goes well at mapping ill be driving it back, for good so to speak.

[peester]

Ive found it a bit tricky ordering the parts over the last few weeks as you have to lay-it-out on the bedroom floor lol, with no car nearby for referance..
If ive missed or forgotten anything - it might be too incovenient for the garage to stop, leave the car half done, stored; waiting for more parts to be ordered..
The 'last of the few' bits came this morning, but for some reason ide ordered 2m of hose and need 3m (to cut into a 2m and 1m lengths)..
So ive now ordered 1m. Then just this bracket welding and fitting.
As well as the fuelling parts ive had to sort oil, filter, plugs, drain plug and recovery to the rr. Little fiddly bits.

[Southie]

... and I'm knackered. Also I must hang my head in shame on not seeing this before.

What a cracking build you've made of this, loving obviously the X18 and bodies, did you manage to sort all the fuelling then as I've noticed it's been a while since your update lol
Really like the ideas throughout your project though, especially the MK1 flocked dash, just seems to give it more of an edge, and the gear selector looks the dogs danglers.

Also what's the plans for this for 2012 besides enjoying driving it are you planning any shows?

Hopefully see this one day and hats off to a very cool car :)

David.

[peester]

lol wasnt expecting to see this , this morning..
Thanks southie. In a nut shell nothing has happened. About 5 days after last update (around 1st July 2011) an opportunity came up to move out of parents home, into my own little flat. So i did. I then proceeded to spend all my nova mapping money on flat deposit, rent in advanced, then it got spent on kitting the place out a bit, then in August i changed my daily hack swapping the tired old Vec for nicer mk4 astra. Then obviously with new bills out goings etc it now just takes me a lot longer to do any saving.
I do still have the car and hope to finish it, it actually plays on my mind loads thats its taken 2 years odd just to get it mapped. But as said, its really tricky , as for anyone really, to save hundreds of pounds up. But hopefully this year i will and it'll happen.
Ive not really yet thought about any 'what if i dont?' scenarios.. Im just glad thus far ive not had to sell up, to fund moving out i guess.

[Southie]

Was it that much of a surprise, almost morning wood lol

Glad you've still got it and haven't had to sacrifice all your hard graft, look forward to you getting the money together and getting this properly setup, also next time it gets mot'd use it lol

Has Mazz still got the cage stored for you lol

[peester]

lol, just surprised someones asking about it . We'll see how it goes, i think the brakes (servo system) may need some attention for next MOT.
I got the cage off mazz a while back, its at my brothers house/garage now so im able to garage my daily car at the flat.

[Mazz]

Thought there was a update then! Nice to see you haven't given up on it or had sell it/stuff to fund the house...Have you got it at your new gaff then now, as iirc you said you had a garage?

[peester]

I guess there is a little more ive done since last update, getting the car prepped for mapping. But pics are on an old broken pc; need to get the hard-drives out of it..
I still keep the car where it was Chris, i actually filled the garage here at the flat with all our unit/lockup junk when we left the farm back in may last year. But since august we've had another lockup, (near stoke :-s ) but not one to keep the car at really - just all our things.
So at least now the flat garage is empty and available but im currently keeping the daily in there.

[nova mad daz]

Just been reading through this tread and may i well done mate thats the muts nuts keep up the good work an get it finished :-)

[peester]

*NotreallyanUpdate
Im having urges to sod it and spend some savings i shouldnt touch to get this thing map'd. lol.
Looking to book it next week i think. Fed up lol.

[scott.parker]

Do it!

[peester]

lol, seems a lil attention seeking of a post by me, but maybe some ideas/suggestions will come about before i make any bookings by giving the thread a bump..
As said years ago, lol - fuelling parts to be fitted , a mini service, mapping and recovery one way. Im hoping the place can help diagnose why where the braking system may need attention, also.
Ill get the garage next door to MEK to try and quote for the work at least; but with that being a stop shop it easier and keeps recovery costs down.

[Riggy]

Yeah Dave , do it , fantastic car :)

[Mazz]

Surely you can fit the fuel parts and do a mini service?

Whats wrong with the brakes?

[peester]

I might be able to struggle through the fuelling system; (ive never worked with these aero alloy fittings) and thats if i can find some ramps for long enough to do the job. But i think ide then struggle to get the car running again with a new pump anyway.
The brakes im not sure, they work poorly, so its not a priority; i think theyre just victim to few years of it standing around. Maybe a newer servo/master cylinder/fluid change or a bit of everything..
As you can tell interest/patience/etc/etc all low, non existant lol.

Ill find out friday if im to go ahead with this gig or not.

[MARTIN KELSON]

Come on Dave pull your finger out.

The aero fittings are simple to do (even i managed it!)

Are you going down simple route with fueling? Tank - Filter - Pump - throttle Bodies - Pressure Regulator - Back to Tank.
No need to over complicate it anymore than that!

Get it sorted :)

[peester]

hey hang on martin - you said even you'de had someone to do it for you...? lol
But yes just the simple route. I guess the mapper i rang ages ago said he'de prefer to have the car running so ive just had it in my head to get the car to them as it is.

[MARTIN KELSON]

I did the fuel lines myself mate :)

When mine was being a pig starting & not running right, its all in that throttle pot telling the ecu where your foot is!

Set it up on voltmeter as per instructions but when you plugged laptop in it wasnt quite right! Once Toovey set that 'right' on laptop it was a different car.

I thought yours started & ran?

[peester]

yeah it does, but ide have to adjust fuel pressure (maybe more?) when changing from a weak fuel pump to a beefy one.

[scott.parker]

Get any parts you think you need, then ask nicely if John H might pop over and help you get it sorted to get it running nice, then get your ass down to Dave at MEK ASAP, the man knows his stuff and will have it running sweet as a nut in no time, and you will be in love with the car once its all done, mine came away from his like a new car, i didn't think mapping was "that important" and would matter as much as it did..

[MARTIN KELSON]

If it starts & runs take it to mapper as they will set fuel pressure etc after you have swapped the fuel pump if thats what your on about doing.

Dont take it then start messing or its just a waste

[peester]

Car gets mapped after fuelling parts are fitted. Not really sure why that mapper wanted it running to begin with. Ive an idea of whats involved in the fitting of the parts; hence getting it to someone cleverer with decent tooling/facilities.

[MARTIN KELSON]

It aint hard Dave, come on you can do it :)

Get those sockets out & crack on!

[scott.parker]

Car gets mapped after fuelling parts are fitted. Not really sure why that mapper wanted it running to begin with. Ive an idea of whats involved in the fitting of the parts; hence getting it to someone cleverer with decent tooling/facilities.


To save you money and him time on the car, as he can just get straight into mapping if runs alright, but if it's not running then hes got to faff doing that first mate, think about it, if you can save that issue you save wasted time and cash!

[peester]

lol see how things go martin.

Yeah scott, i kinda thought it'd help.

[scott.parker]

Well in total Dave spent about 3-3 1/2 hrs mapping mine, then we did two sets of 4 (so in total 8) power runs, after the first 4 he tweaked and altered things slightly to get a few more bhp and lbft's out of it, and get it spot on, so from getting there and leaving i think it was about 4 1/2 hrs, so you see if he need to faff with it, then you might have to make it two days worth! and that going to cost you...

[Mazz]

Arrange at weekend date for a mince..

[MK999]

Car gets mapped after fuelling parts are fitted. Not really sure why that mapper wanted it running to begin with.

We got a car in for a megajolt map recently, drove in on a dizzy and just needed the ECU plugging in and mapping, all the wiring was 'done'.

It's still here about a month later after frying the ECU, the TPS being fitted at -20% on solid bolts with not enough adjustment, and needing the ECU loom redoing, then developing a misfire which is yet to be diagnosed.

That's why he wants it running lol

[Dave.]

http://img.photobucket.com/albums/v11/peester/IMG00250-20110313-1316.jpg

Looks absoloutley spot on here! Love the wheels, Loving it! :thumb:

[peester]

thanks for the comments.. the lads are right; im a bit reluctant to break out the spanners these days; but thats not why its still not finished lol.
Ill update after the weekend , sort a few other things first.

[Mazz]

If you need a chunk, gimme a phone!

[Titz]

What modification it takes to change the clocks color light ?
Thanks

[peester]

disassemble clocks, fit a transparent blue film/filter between bulb and panel.

[SimonTW]

Can't believe I missed this thread. Awesome car.

[Danb1987]

Just read this thread from beginning to end :thumb:

Absolutely brilliant build thread matey, agreed with everyone on the shifter! It looks mean as Fook!

Top work buddy :)

[peester]

thanks chaps. Mids meet at the weekend has also helped spur me on a bit lol.

[Mazz]

good good :) be really nice to see around again...

[mowgli]

how could we have spurred you on?????? lol lol

we ate food, and then stood around talking, except turbolocks, who went off on an emergency call out!

[peester]

yeah ok, that bit was boring - i meant the sunny day driving down, looking at them then driving back.

[Mazz]

If i'd have thought, you could have driven back!

[Mazz]

I'll bump this while I'm here looking for pics!

Any updates Dave?

[peester]

car is at Bowyers, he will be mapping it - once Ian Evans has replaced the fuel system and given it all a once over.
Doesnt look its going to make billing though.

[Mazz]

:(

[peester]

*Update.
Car is back.
http://img.photobucket.com/albums/v11/peester/IMG00954-20120827-1423.jpg
To back track, bring up to speed; i decided at the beginning of the summer to go with martin bowyer and ian evans to have the car finished for me. I realised that would take a while, but costs would be a bit better than usual, and theyre great guys i like dealing with them. I wasnt really able to do the jobs that were left; time to get experts in.
Originally i planned to go with dave young @ MEK but changed my mind.
I had concerns with well pretty much everything, because i built most of it and the car has done about 30 miles since 2009. So the scrap yard sourced vectra b z18xe thats been sat mis-mapped since 2009, an f15cr gearbox from nick baxter (!) brakes that have never worked very well, exhaust heatwrap that still smokes its bag off since last year,.. loads and loads. All 87 pages of this thread.
I gave them a new complete fuel system to fit (lines filters pump aeroquip fittings from the tank to injectors) fresh oil and filter and anything else it needed. Requested they check over the car thoroughly, sorting what might need improving etc - for they're own safety and others.

In the end non of that happened. Car wasnt finished for me, they just mapped it as it was lol.
I was suprised to hear it had survived lol.

However, its just good that something has been done and its back without a hitch. Ive been out in it all weekend, feels good. Glad ive finally reached the milestone that the car is useable.
The objective of this whole project was to build something that has proper Jenvey Throttle Bodies. Ive wanted them since seeing them in action at velos motorsport back in 2002ish..?
They kick ass. I love the way a refined civilised modern engine becomes this possesed crazed brutal devil that only knows 'as fast (and loud) as i can'.
Feel 19 again lol.

[Mazz]

Happy days eh! If your out later, call round!

[peester]

what now?

[Mazz]

Can do! I'm only gonna mong around the house of a bit and watch a film...

[peester]

ill be up in an hour, hows that?

[John]

vids! Must take vids and post on here later :)

[Mazz]

Fine, see you in a bit..will do John!

[Adam]

Good news Dave :)

[Iain]

Nice to see you've got it back and happy with it again. It's easy to have doubts in the work you've done yourself (I was proper scared of the first few hundred miles in my Nova) but sometimes all it takes is someone else to give it a good testing and prove it's up to the job.

Please remove those white stickers from the rear window. lol

[MARTIN KELSON]

Nice to hear its back Dave.

Blimey Dave you been out today, its been proper wet over here!

Iam always worried with mine Iain for first few miles, you hear a knock or rattle & think its something youve not done up properly :)

[peester]

Thanks all, i havent been out in it today- weather did turn after me and chris talked of meeting up, but it was more the state ive been in today that made me change my mind. Ill catch up with chris in the week perhaps.
Yeah theres a lot more to the story than ive said in the update, but in answer to the 'someone else to give it a good testing' it literally got raped for a week by a rally driver so im amaized it survived that treatment as well as the rollers.
My maiden voyage was a 75 mile journey back from bowyers so that did a good job of restoring some confidence, faith.
Its hilarious to drive at the moment because the throttle cable ive used is a bit taught, so the response is o.t.t, tricky to pull away gently, calmly.

[peester]

Bit of an update, follow up since picking the car up a few weeks ago.
Been using the car as much as poss, enjoying every minute. Was at Mazz's for a bit on saturday..
http://img.photobucket.com/albums/v11/peester/219499_10151887693710752_981330713_o.jpg
It was there when i discovered ive got a new leak;
http://img.photobucket.com/albums/v11/peester/DSC01196.jpg
Looks like its the selector to gearbox gasket..? I thought for a moment it might be the shifter rod seal at the gearbox but that looks dry.
http://img.photobucket.com/albums/v11/peester/DSC01193.jpg
There also is a leak from the sump thats been there a while now, i think a new gasket will sort that.
Ive got another throttle cable to try, oil and filter for a mini service.
But on the whole, the feedback from ian, martin and my own experience/findings its just a few tweeks/alterations that will be on going over winter, into next year.
He gave me a small list of imperfections so plan to do those. The fuel system that didnt get fitted will need doing. I have some wiring to tidy for the fan, some changes there too. The shifter needs a bit of fettling. Exhaust system needs upgrading, better fitting.
I want to look into u.j's ; see if i can replace the o.e vauxhall astra mk1 plastic one, like in the above photo of the gearbox leak..
Anyone got any ideas/opinions on that..?
Im also going to have some bodywork touched up, new bonnet, some paint.. im experimenting with a slightly different look; bumpers, wheels.
I guess it'll be the final 'stage' - dotting t's and crossing i's as such.

[nova mad daz]

Not read this thread for a while glad to here your havein some fun in it after all your hard work epic build mate love the car an the colour

[John]

Car has come so far Dave! Congrats on the mag feature! :)

[Mazz]

Feature? Is it out yet?

[John]

Feature? Is it out yet?

Yes Chris, this months retro cars :)

[peester]

Thanks again John, yeah I kinda didn't bother with the build thread; but ill throw up some pictures I had taken during last year to 'finish' it for RRG'13 that August.. which is where it got discovered, for the feature.

[Benn]

Think you should, would like to see everything thats been done.

[dgbnova#1]

We had a good chat at Pvs some great little trick ideas on you car and handy info for one of my builds well done with the feature will go find a copy

[peester]

I lost a lot of photos of work that went on during 2013 due to not backing-up/uploading them before the phone went faulty and needed to be sent for repair. So I don't have much.
For now, I can go through what photos I have to take it up to the beginning of this year.
--------------------------------------------------------------
By the end of 2012 the x16xe sump that RetroPower had modified and fitted for me was weeping oil.
http://img.photobucket.com/albums/v11/peester/DSC_0216_zpse575063a.jpg (http://smg.photobucket.com/user/peester/media/DSC_0216_zpse575063a.jpg.html)
So I took it off and decided to look to going back to the original Z18XE one - but it would also need modifying to fit around the BTB manifold I was running also to be shallower; the same depth as the X16XE sump.. which is why I used the x16xe sump in the first place. It was thought the circled in photo oil drain ways were a cause as they are positioned over the flange and gasket on the X16XE sump. In addition, I had been running the X16XE sump without the top baffle/crank scraper.
http://img.photobucket.com/albums/v11/peester/DSC_0094_zpse77d06cd.jpg (http://smg.photobucket.com/user/peester/media/DSC_0094_zpse77d06cd.jpg.html)
Anyway, I spent some time working out how the Z18XE should be modified before later in the year sending it off the Adam Dewis Motorsport for the modification.
In the mean time during Feb '13 I sent the car off to get the front valance resprayed/tidied up in preparation for its 'new' but old, original front end set up. Deciding to ditch the deep GTE bumpers. At the same time I was working on the top, under slam panel radiator fixing.
http://img.photobucket.com/albums/v11/peester/DSC_0135_zpsd6bc8951.jpg (http://smg.photobucket.com/user/peester/media/DSC_0135_zpsd6bc8951.jpg.html)
The black mk1 grill and faded grey mk1 front bumper were treated to black plasti-dip and fitted.
http://img.photobucket.com/albums/v11/peester/DSC_0144_zpsd5586a25.jpg (http://smg.photobucket.com/user/peester/media/DSC_0144_zpsd5586a25.jpg.html)
In May '13 I was to start the sump swap over, fitting Adam Dewis' modified Z18XE sump. It just about fit into place and for a little while all was well. Look; a completely newly made from scratch sump bowl:
http://img.photobucket.com/albums/v11/peester/mms_20130430_5_zpse687da03.jpg (http://smg.photobucket.com/user/peester/media/mms_20130430_5_zpse687da03.jpg.html)
Also sorting the engine mount - it needed a new hole drilling slightly higher to raise one side for the engine to sit more level, so got that done. Had the two original holes plug welded of course.
http://img.photobucket.com/albums/v11/peester/DSC_0283_zps2f8c3c15.jpg (http://smg.photobucket.com/user/peester/media/DSC_0283_zps2f8c3c15.jpg.html)
Whilst it was off an area of corrosion behind the engine mount could be sorted..
http://img.photobucket.com/albums/v11/peester/DSC_0278_zpsf12401bd.jpg (http://smg.photobucket.com/user/peester/media/DSC_0278_zpsf12401bd.jpg.html)
http://img.photobucket.com/albums/v11/peester/DSC_0285_zps854efc79.jpg (http://smg.photobucket.com/user/peester/media/DSC_0285_zps854efc79.jpg.html)
http://img.photobucket.com/albums/v11/peester/DSC_0296_zps161614a5.jpg (http://smg.photobucket.com/user/peester/media/DSC_0296_zps161614a5.jpg.html)
http://img.photobucket.com/albums/v11/peester/DSC_0314_zps800c8653.jpg (http://smg.photobucket.com/user/peester/media/DSC_0314_zps800c8653.jpg.html)
http://img.photobucket.com/albums/v11/peester/DSC_0320_zpse5ec7e4c.jpg (http://smg.photobucket.com/user/peester/media/DSC_0320_zpse5ec7e4c.jpg.html)
http://img.photobucket.com/albums/v11/peester/DSC_0326_zpsfe60ed10.jpg (http://smg.photobucket.com/user/peester/media/DSC_0326_zpsfe60ed10.jpg.html)
Refitted the mount, engine back in a better position.
http://img.photobucket.com/albums/v11/peester/DSC_0327_zpsb783a2a0.jpg (http://smg.photobucket.com/user/peester/media/DSC_0327_zpsb783a2a0.jpg.html)
Two other jobs under the bonnet were - a new, more functional oil catch tank. Relocated to the firewall/bulkhead to tidy the engine bay a bit more also a CM Composites custom made carbon fibre spark plug/coilpack cover:
http://img.photobucket.com/albums/v11/peester/DSC_0420_zps54b55a0f.jpg (http://smg.photobucket.com/user/peester/media/DSC_0420_zps54b55a0f.jpg.html)
With the front end complete; all that was left was to plasti-dip and fit the o.e spec. rear bumper. New wheels too, of course. Luckily I ordered the set of 4 5.5J x 14" TH Comps in ET45 just a few weeks before Compomotive closed its doors. Last 4 stud Vauxhall friendly set..?
http://img.photobucket.com/albums/v11/peester/DSC_0474_zps130de390.jpg (http://smg.photobucket.com/user/peester/media/DSC_0474_zps130de390.jpg.html)

[peester]

Made it to RRG'13 all sound and happy.
http://img.photobucket.com/albums/v11/peester/1170778_590668504330392_1604407931_n_zps2115e85f.j pg (http://smg.photobucket.com/user/peester/media/1170778_590668504330392_1604407931_n_zps2115e85f.j pg.html)
After having a note left on the windscreen asking me if I would like it featured in Retro Cars magazine, in October '13:
http://img.photobucket.com/albums/v11/peester/DSC_0016_zps51c04959.jpg (http://smg.photobucket.com/user/peester/media/DSC_0016_zps51c04959.jpg.html)
http://img.photobucket.com/albums/v11/peester/DSC_0017_zps7bc8c238.jpg (http://smg.photobucket.com/user/peester/media/DSC_0017_zps7bc8c238.jpg.html)
A couple of months later, Dec '13 - the Z18XE sump was leaking again. My thinking; the flange/ mating face was too warped from the welding/modification. I left it over winter, had enough of sump lark for one year.
I shall have a better look for photos maybe take some new ones of the parts I've fitted - some that can't be seen easily. I shall do another update of what I did during this year in a day or so.

[staggy_gsi]

Really liking how this is looking nowadays!

[Nick J]

Looking great fella!

Nick.

[nova_niek]

Liking the blue and plastidip antracite combo :thumb:

[kevw]

Yea I also like. Good work.

Did you use the aerosol Plast Dip? I'm wondering whether to use it for the bumpers on mine, I guess you went for matte black?

[peester]

I did yes. Aerosol. I didn't use the primer/undercoat though, I think next time I should; might help it 'stick' better - withstand more abuse, be a tad more hard wearing.
I don't think it was mate black no - I was worried it would be bbq-esque. I went for satin black I think.

[kevw]

I like the look, might give it a go.

Would you be able to peel off the Plasti Dip like you see on the videos?

[peester]

With the primer first, I don't know.. I've not tried it. It doesn't look very tightly stuck down without the primer though.

[Mazz]

Any scans of the feature Dave?