Tom's 1600 T40 Wide Arch, Wide Track Nova [Archive] - Performance Nova Group

tom_beverley

14-07-07, 10:15 PM

Hi,

Some of you will know part of the story as I've posted a few pics in a seperate thread.

It began about 4 months ago when a mate gave me a C14NZ block. I had planned to build up a fresh 1400 motor but after a bit of a think I decided to go for 1600. Anyways, finding a E16SE or C16SE block proved very difficult so I did my research and discovered it was possible to put 1600 internals in the block, I just needed them now! So, a Wanted Part thread later I had found some (thanks Craig!).

My current engine spec is:

C14NZ block bored out to 79.5mm then stripped and cleaned methodically
0.5mm Oversize Mahle pistons
Deseamed Rods
ARP Rod Bolts
Balanced C16SE crank
New ASL Lead Copper Heavy Duty Mains and Big End Bearings
Modified Oil Pump (courtesy of Tom Reid)
Fully Lightened and Balanced Flywheel
Whole Rotating Assembly Lightened and Balanced
New Waterpump
C16XE baffled ally sump
New Seals & Gaskets
Sachs 4 Paddle Clutch and Uprated Cover

Cylinder Head Developments B+ equivalent E16SE head fully ported and polished, 3 angle valve seats, with 39mm Inlet, 33mm Exhaust, Kent uprated valve springs
Kent AST2 Cam
Kent Vernier Pulley
Inlet will be port matched to head**
Reconditioned T40 Dellorto carbs
Heatwrapped Lexmaul 4-2-1 Manifold
Custom 2.25" Stainless Exhaust (removed middle silencer) with Peco backbox**
Brand new original Bosch 1.4SR dizzy
Magnecor KV85 Ignition Leads
NGK Platinum plugs

F13 CR Gearbox with 4.18FD
Rose jointed gearlinkage
May look into internal shifter

**Not done as yet

Stripped down block
http://img.photobucket.com/albums/v147/tom_beverley/New007-1.jpg

I managed to locally source (via ebay) a nice Sachs 4 paddle clutch plate and uprated cover, and also a vernier pulley off the same bloke. When I received them I sent the crank, rods, pistons, flywheel and clutch cover to get lightened and balanced and got the C14NZ bored out to accept the new +0.5mm pistons. Also managed to save enough money for Chris Astley solid engine mounts and a chassis strengthening kit so the shell is done for any future engine conversions. Thanks to Chris aswell for getting these to me very quickly as I explained I was hoping to make PVS

Crank in
http://img.photobucket.com/albums/v147/tom_beverley/New009.jpg

C16XE aluminium sump is baffled to prevent oil surge and the Mahle 0.5mm oversize pistons with rods and big end caps
http://img.photobucket.com/albums/v147/tom_beverley/New014.jpg

New ARP bolts
http://img.photobucket.com/albums/v147/tom_beverley/New024.jpg

Paddle clutch and vernier
http://img.photobucket.com/albums/v147/tom_beverley/Picture008.jpg

Finished article
http://img.photobucket.com/albums/v147/tom_beverley/NovaBuildEndjune07011.jpg

By the time of this it was nearing PVS so was in abit of a panic to get it all done but there was no chance without cutting corners which is the last thing I wanted to do. Gutted

Whilst the engine was out I decided to tidy up the bay a little, strip the interior to just a dash and buckets and relocate the battery to behind the passenger seat as done by R1CH (thanks for the info). Whilst re-routing the wiring I noticed a bit of silicone at the top of the passenger footwell so had a poke at it and it sounded lovely and rusty behind it. So, out with the wire brush and I created a nice hole :mad:

From inside
http://img.photobucket.com/albums/v147/tom_beverley/NovaBuildEndjune07003.jpg

From the bay
http://img.photobucket.com/albums/v147/tom_beverley/NovaBuildEndjune07002.jpg

So I nervously tackled the drivers side wary of what I was going to find and unfortunately it was just as bad

http://img.photobucket.com/albums/v147/tom_beverley/Nova29thJune07019.jpg

tom_beverley

14-07-07, 10:26 PM

Interior stripped bar those horrible bits, I need a hair dryer for those lol Floor is surprisingly good! (about the only bit!)
http://img.photobucket.com/albums/v147/tom_beverley/NovaBuildEndjune07021.jpg

Another snap of the drivers side footwell
http://img.photobucket.com/albums/v147/tom_beverley/NovaBuildEndjune07030.jpg

Going round the car rust hunting I found the rear of both sills were cr@P so will eventually get new sills on when I fit the wide arches and get a respary but for now will get de-rusted and patched up neatly.

I decided to just strip the whole front end by this point and was getting pretty disheartened as my car is a wreck :cry:

http://img.photobucket.com/albums/v147/tom_beverley/Nova29thJune07006.jpg

http://img.photobucket.com/albums/v147/tom_beverley/Nova29thJune07001.jpg

http://img.photobucket.com/albums/v147/tom_beverley/Nova29thJune07015.jpg

Inside looking at the N/S rear arch/sill
http://img.photobucket.com/albums/v147/tom_beverley/Nova29thJune07024.jpg

tom_beverley

14-07-07, 10:36 PM

This week I've been busy prepping the car for the welder to help and to save money. Also gives me the chance to know more what the car is like and where it needs attention as no doubt I'll notice all the little bits. Also I decided to remove the firewall but I've retained the standard wiper motor for now until I do a little more research about the Citroen AX one. I'm getting the chassis plates welded in and also the shell stich welded so it is strong, again, incase of any future conversions and also to prevent any more corrosion due to spot welds.

Seams stripped down
http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07005.jpg

http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07007.jpg

Bulkhead getting removed
http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07006.jpg

I found some clean metal!
http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07001.jpg

Front arch stripped down
http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07003.jpg

Extent of corrosion
http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07002.jpg

Another sealer bodge exposed (yes thats my foot!) :eek:
http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07011.jpg

Chassis legs ready for strengthening
http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07015.jpg

tom_beverley

14-07-07, 10:41 PM

Extend of more corrosion
http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07019.jpg

Shot of turret
http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07025.jpg

I left the bit for the wiper motor
http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07035.jpg

See ya!
http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07034.jpg

My current trusty runaround
http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07032.jpg

Passenger side front arch stripped
http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07036.jpg

http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07039.jpg

http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07038.jpg

http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07042.jpg

tom_beverley

14-07-07, 10:45 PM

Cleaned up turret tops
http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07043.jpg

http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07044.jpg

http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07047.jpg

Not a bad day today, got quite a lot done and not many more suprises :)

Finished at about 8pm and left my baby like this
http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07045.jpg

http://img.photobucket.com/albums/v147/tom_beverley/Nova14thJuly07046.jpg

shy witness

14-07-07, 10:53 PM

afew nasty surprises there mate......but they could b fixed alrite.....

its not so bad when ur actually going to weld up the whole shell anyway(from a strengthining point of view)

it means you can kind of incorporate more strengthening.........whilst cutting out and repairing the rusty bits(well thats what im telling myself anyway lol)

good luck mate................but i think your doing a good job so far

burgo

14-07-07, 11:01 PM

as for the wiper motor, get yourself a corsa mate. all i did was welded a washer to the wiper assimbly and used a riv-nut to bolt it to the bulkhead. plus being as it a corsa one you just have to extend the wires abit

tom_beverley

15-07-07, 04:06 PM

EdnovaScooby

15-07-07, 04:20 PM

wow loads of man hours put in there!

burgo

15-07-07, 04:54 PM

Haven't looked at a corsa one tbh, have you got any pics of yours?

Did a bit more dieting today lol , gone are the unused bits of metal on the floorpan, must get it to below 700kg then I'll be happy. fancy putting a Corsa bias pedal box on and removing the balance bar assembly but that can wait for now until I can afford it!whilst youve got the welder out you may aswell do the corsa brake servo mod now, its easy enough. heres a pic of how my servo and motor sit, basically exactly the same way as in the corsa
http://i12.photobucket.com/albums/a226/sclurgess/nova9.jpg

tom_beverley

16-07-07, 11:05 AM

Thanks for the pic!

I would do it now but I don't have the time, I'm not doing the welding as I want it doing really nicely lol The car is going away tomorrow so I won't have the chance to get it all lined up and worked out and I just want to stick a bias pedal box straight in there and can't afford it either!

Its definately a job to tinker around with and get just how I want it when I pull it off the road for winter.

My main aim this year is to just get the car rot free and strengthened, then get it setup and RR and back on the road for Trax - PNG's 1st official show. I've got a brand new Walden wide track kit and wide arches ready for when i can afford a respray so by next year it should look good enough to eat ;) Of course accompanied by some lovely 16" white comp mo's but I quite like the RSGT 5 spoke alloys aswell.....

craig green

16-07-07, 02:41 PM

Nice write up Tom.

Most Novas hide bad rot I find. Good luck with having the welding work done, the worst is nearly over as when it looks that bad its hard to see a way forward.

Adam

16-07-07, 03:27 PM

FOoookk, suprising how much a bit of sealer can hide.

Be good to see it welded and sorted :)

gammienov16v

16-07-07, 03:32 PM

get it done, i put an 8v in my van it went well too!!!

good look:thumb:

tom_beverley

16-07-07, 06:25 PM

Daft as it sounds I can't wait to see it back all welded up :D

When removing the firewall, whats the best thing to do with the bit thats left sticking up? Hammer it down and weld it or just grind it down/off?

When the car gets back I've got all the bay to prep and spray up, going to zinc primer it and filler primer I think to get it nice and smooth. Interior will also be prepped a little and sprayed, hoping to get a nice finish using cans though!

Fuel lines are going inside aswell, brake lines can stay as they are for now, I can tackle them later on.

Got my alloy battery tray/box the other day, will look nice!
http://img.photobucket.com/albums/v147/tom_beverley/Nova29thJune07027.jpg

gammienov16v

16-07-07, 11:59 PM

hammer it down weld it and seam seal it then paint.

that easy:thumb: thats wot i do;)

were did you get the battery tray from?
it sould solve the rusting problems you can get nasty:cry:

draper

17-07-07, 09:01 AM

some good work there matey

tom_beverley

17-07-07, 09:17 AM

Bit of an update, removed the horrid sticky pads from the floors to discover a few more holes, one is right where the floor is spot welded to the chassis rail and is pretty big :( Ah well it can be fixed, glad I removed them before it goes away tonight though.

Also rust is apparent along parts of the rear floorpan seam (behind the front seats) so will need to be stripped underneath and investigated :( May aswell get that stiched too. Plus side is the areas around the drain plugs are rust free but they are getting plated over anyway.

Forgot the camera last night though so no pics yet!

gammienov16v

17-07-07, 01:27 PM

get it welded up lol

tom_beverley

18-07-07, 09:07 AM

Well the Nova went away last night, looked wierd going away on a trailer and it didn't take long for the rumour to get round I'd scrapped it lol

Speaking to Jim (the welder) about what I need doing again since I've found more holes and list is:

Seal inner wings off
Refurb inner wings
Refurb inner arches
Fit chassis kit
Stitch weld shell, chassis legs
Tidy up firewall seam
Fab in the rear turrets
Seal all drain holes on floor pan
Chop out as much rot as he can find (there will be nothing left lol)
I might just get two new sills put on now aswell so its all done
Also got new rear panel to go on

I wouldn't of thought I'll see my car back for a few weeks so I've got a few things to get on with in the mean time. With the engine just sat there I thought I may aswell triple check everything is done just in case I have missed anything or something is not torqued up properly. I'm still awaiting my 1600 T40 inlet so when that comes I can match it to the head and then assemble the whole engine and time it up ready :cool:

I wish I had more money to get it sent from Jim straight to a bodyshop to get it all sprayed and my wide arches on :mad: Ah well, at least this way I can enjoy it for a month or so before it comes off road for the winter. Reminds me, need to find a garage to keep it in...

draper

18-07-07, 09:20 AM

id be very tempted to get the sill aswell, no point having it all stripped down to only do half a job ;)

gammienov16v

21-07-07, 08:57 PM

this is my old 2.0l 8v vanhttp://i184.photobucket.com/albums/x49/jodiepp/Menov2.jpg?t=1185047401

tom_beverley

31-07-07, 03:10 PM

Just a small update really...

Car is currently getting welded, still not sure whether I'll be getting it back by the time I go on my holiday on 10th August, not too fussed really as it would just be sat there whilst I'm away.

Hopefully my new 1600 T40 inlet will arrive soon as thats delaying me matching the ports and getting the engine all built up complete.

Been spending too much lately, running the plastic up a little too much than I feel comfortable with, I think I'm addicted to buying Nova parts lol

Recent spec additions are:

Tran-X LSD (2nd hand at ?325.00 delivered, not bad if you ask me)
Sparco adjustable alloy side mounts (no seats yet though lol)
And a few other minor bits

Next time I go see the car I will be taking the camera so will get a few pictures.

Adam

01-08-07, 12:32 AM

How much is the welding costing if you dont mind me asking?

It looks quite a repair list,Lol.

tom_beverley

01-08-07, 08:59 AM

Yes its quite an extensive list, the honest answer is I don't know yet :(

Originally he came and had a look at the car to give me a price and that was ?300-?500 depending on if there were anymore surprises with ?500 been the worst scernario.

Since then I acquired a new GM rear panel as mine has a hole in it, asked that to be fitted whilst also adding the rear turrets to the list so tbh I'm not looking forward to the price.

Saying that he is a nice bloke and was recommended to me by a friend who sends a lot of work his way. Since there is so much to weld hes doing it a bit cheaper so I will just have to wait and see (and pray) it won't be too bad.

Its the kind of list I'd want to do myself but having no welding experience I just wanted to get it done properly and at least it gives me a breather from my dad's constant whining about I'm taking over his unit.

craig green

01-08-07, 09:27 AM

Sounds good Tom. You definately have the right idea of getting someone else to weld it properly & save your learning curve for some other metal..

Good price on the diff too.

tom_beverley

02-08-07, 03:51 PM

Cheers,

Did a little more painting last night, my fingers (and elbow for some reason) are still silver today at work which looks good lol

Got some white spirit to clean everything down as I thought I may aswell get it all clean. Cleaned my new head up and came up pretty nice, managed to get the inlet side painted up with silver Ronseal and left that to dry over night. The brake servo, starter, oil pump, and coil got the silver treatment. I gave the block and sump another going over aswell as I thought another couple of thin coats won't do any harm. The wiper motor and coil bracket received some satin black spray too which brightens them up a little.

I'm thinking I might get some plastic primer and do the cambelt cover in flame red, not sure though might look a bit ****e

Checked the block over to make sure all gaskets were installed, everything torqued up etc. The one bit I'm not happy with is when I installed the end main cap (above crank end seal). In Haynes it says make sure the channels either side of it are filled entirely with instant gasket to remove any air.

Is this vital? Just the sealer tube I have wont go in the hole at the top very well.

My new side mounts arrived on Tuesday, still waiting for T40 inlet, eccentric top mounts. I should also have the LSD by the weekend which is the main thing I can't wait to turn up :D

corsa_valver

02-08-07, 05:37 PM

loooking good! some serious repairs going on there!

tom_beverley

07-08-07, 09:38 AM

Update,

Got my Tran X diff last night :D but left the unit key at my girlfriend's flat so couldn't fit it :( Never attempted one before but when I bought the gearbox the lad had it all stripped down so the castle nut shouldn't be too bad to remove.

Still waiting on alloy eccentric top mounts and T40 inlet (inlet has taken nearly 3 weeks :mad:) I really need the inlet before I go on holiday so I can take it get port matched to the head so when I come back the engine is all ready to go in, otherwise I'll be attending Trax in the Pug :roll:

tom_beverley

27-08-07, 02:05 PM

Back off my hols now had a really nice time apart from it just rained for the last week and was sunny when we were driving home :( Go karting in the rain is awesome though! Anyone thinking about going to the Vendee region in France I'd recommend it, loads to do and was lovely and hot in the first week.

Still awaiting the inlet so I'm not happy with how long thats taking to arrive :mad:, got my eccentric alloy top mounts :), also bought a new rear bumper with numberplate recess in.

Pics will follow shortly when I get back into the usual routine (I'm missing my holiday) :(

ashjones

27-08-07, 03:07 PM

just wondering about the servo mod i take it that gets rid of the bar that goes across the bulk head what corsa is it off and is it easy to do cheers

tom_beverley

31-08-07, 09:12 AM

I haven't attempted this yet so I cannot say how difficult it is. By what I've read as long as you can use a welder and have a bit of fabrication skill its not too difficult.

The benefits are primarily to save weight by removing the balance bar that runs across the bulkhead. Some people also say that the pedal feel is also improved due to the direct action.

Something to play with over winter :D

scott.parker

20-09-07, 07:50 PM

Jeees Tom...

I just looked at the poor old gal, and to honest mines not as bad as that (well it could be worse but im not going to find out)
Im scrapping mine as i cant see the point in spending so much money on repairing it all, it's ok if you can do and have the space to work on it your self, but otherwise mate i would of re-shelled it.

Just my opinion.

Scott

tom_beverley

21-09-07, 05:35 PM

Yes it was a right rot box of hidden treasures :( I was close to giving up and reshelling it tbh as it really disheartened me.

I'm glad I didn't now though as its now totally my own creation, plus been a van makes it that something a little different. Its pretty much rot free now, still a hell of a lot of work to do but its getting there slowly.

Pics will follow tomorrow...

tom reid

22-09-07, 08:20 AM

Nice project there Tom, the price for the welding seems quite good.

tom_beverley

03-10-07, 08:47 PM

Time for an update with pics at last, after forgetting the camera on numerous occasions :wall:

Still a couple of weeks to go until the car is all welded up 100% so its unlikely I'll make Bruntingthorpe although I'm pushing to get it back in a week but theres a lot to do and I'd rather have it done properly. The new GM rear panel is almost finished now, and the front end is 95% complete and its amazing how much the stitch welding and plating kit has stiffened up here. I'm dropping the petrol tank off to inspect above it and either buy a new tank or refurbish this one. Sills are still to do and inner ones are to refurb if necessary. The seam which runs across the car behind the front seats is all cleaned up and stitched now and the rear turrets are next on the list so some more interesting updates to follow.

Some good news is that I've just managed to buy the very last F10 SCCR input shaft for my cluster from Harry Hockleys after some sound advice from Chris to get one snapped up before its too late! The gearbox box stands me at ?640 which still is not bad for a excellent condition SCCR box IMO. Dismantling and re-assembling the gearbox is not a job I'm looking forward to but its all a learning curve, I just hope it all works when back together :wtf: According to Martin at HH I'm pretty much near the limit for the F10 box if I can squeeze 150bhp from my engine so I cannot afford to damage this input shaft!

I've still got some side mount seats to buy, I'm thinking about the Corbeau Sprint ones as they look nice and have heard a few positive comments on them. It will be either those or the Magnum Pro ones as I really need them to be as light as possible but well priced. Also on the look out for a fibreglass tailgate and bonnet, would love a pair of doors to come up but after buying the new input shaft im a bit skint flint at the moment (only a week after pay day :cry:). I'm still awaiting the inlet manifold I payed for ohhhh, almost 4 months ago, if nothing turns up soon I feel a pi55ed off post popping up in general chat and an informative sig on the cards which I don't want to do but not much choice left :mad:

Sorry about the darkness of the pics but the car was in a dark spot.

http://img.photobucket.com/albums/v147/tom_beverley/Nova3rdOct07001.jpg

http://img.photobucket.com/albums/v147/tom_beverley/Nova3rdOct07002.jpg

http://img.photobucket.com/albums/v147/tom_beverley/Nova3rdOct07003.jpg

http://img.photobucket.com/albums/v147/tom_beverley/Nova3rdOct07004.jpg

http://img.photobucket.com/albums/v147/tom_beverley/Nova3rdOct07007.jpg

http://img.photobucket.com/albums/v147/tom_beverley/Nova3rdOct07005.jpg

novalovingned

03-10-07, 09:08 PM

glad you stuck with it! i know how disheartining it can be, well done on the progress:)

shy witness

03-10-07, 10:12 PM

good on ya mate....and fair play to ya for saving another nova fromn the scrapyard

im hoping to get started on the welding of my own here in the next couple of weeks

i just got my cavalier on the road today for some winter driving.and its almost finished

then its straight into nova mode

the strengthening plate kit should b here by the end of the week....then its time to get crackin

tom_beverley

13-10-07, 12:03 PM

Hello all,

I've had another look at my van this morning and took some better photies as the last were pretty dire tbh, so this time I equipped myself with a flash lol

Work has just started on the rear turrets which IMO looks as if they had been cut down too short, take a look for yourself but looks as if they will be a bit more plating needed than I anticipated. Rest of the car is spot on and very solid, new sills on now too so its getting there now :)

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007009.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007010.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007011.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007012.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007013.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007014.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007020.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007021.jpg

tom_beverley

13-10-07, 12:06 PM

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007015.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007017.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007018.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007019.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007022.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007023.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007024.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007025.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007027.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007028.jpg

tom_beverley

13-10-07, 12:08 PM

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007029.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007030.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007031.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007032.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007033.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007034.jpg

http://img.photobucket.com/albums/v147/tom_beverley/NovaBuild13Oct2007035.jpg

Martin

13-10-07, 12:56 PM

Wow i forgot all about this thread, jus read it from the start..

phuck me it was bad, makes me look like a puff for getting rid of my white shell for having a few bits of rust,. and tbh my new shell isint much better then ures well the front end isnt.

good luck with it mate. if only i could find the motivation to get to work on mine

Adam

13-10-07, 01:20 PM

Fook me, looks like some proper welding work has bee going on.

At least it'll be 100% solid when done :)

Hate to think how much its costing tho,Lol.

tom_beverley

13-10-07, 01:47 PM

An agreed ?500, although I think it may be a teeny bit more as I've asked for a couple of additions. Good price, as it will be fully welded and rot free when finished. Fuel tank is off now too and no suprises thankfully, unsure wether to go for an alloy internal tank or just to refurb this one and put it back on.

Then its time to save for the respray and wide arches, should have this in progress around January time realistically. Soon I'll be taking my wide track kit to get powder coated along with a few other bits and when I get the car back the dash will be coming out to make space to do the EPAS and corsa servo mod.

EDIT and not to forget all those lovely hours ahead stripping all that underseal off the undercarriage and paint up!

shy witness

13-10-07, 04:32 PM

gosh

that was bad

get it well painted and sealed mate..when the weldings all done

Rickyb

28-10-07, 05:18 PM

how is this van doing now then any updates?

tom_beverley

28-10-07, 11:12 PM

No updates yet sorry! I'm still awaiting the car back at the moment, should be this week fingers crossed then I can crack on prepping the bay and rustproofing the repairs.

I'm not sure whether to completely smooth the bay. I like seeing the seams but as sooo much welding has been done I'm unsure if I leave them open it may look untidy. the key is getting everything sealed properly as the last thhing i want is for it all to start rotting away under the filler :(

Rickyb

29-10-07, 09:02 PM

dene

24-11-07, 10:12 PM

Hey up Tom . Could really do with having a word with mate if at all possible .
Cheers Dene .

tom_beverley

27-11-07, 02:52 PM

Bonjour,

Its been a while since I've updated this.

Bad news really, after getting the car back (trailored in the rain :() and spending two full days rubbing down and about two litres of thinners its become apparent that the welding is not upto the best of standards. Basically, I was going to keep the new inner wings and front panel for any future restoration but now I'm going to have to go back to square one, grind all the new welding off and start over installing the new inner wings.

The welding is structurally solid, but messy. I was assured he would do a nice, tidy job and tbh he has pretty much ruined the shell by unnecessary plating. I was looking over with the bloke who will be spraying the car discussing how work is required to get it to a decent standard for him to paint, his exact words were: "A hell of a lot!" I'm leaning towards just replacing everything so its neat rather than grind and fill over everything.

So, after paying the welder ?300 I've now written a lengthy list with everything not up standard and going to argue the toss over the outstanding amount.

Martin

27-11-07, 03:18 PM

thats a ****ter mate any pics?

if you need a hand with anyweldin gimme a shout..

tom_beverley

27-11-07, 04:21 PM

Yeah I've got a few pics, basically it hasn't changed since some of the 'progress' welding pics. I assumed he hadn't finished those bits so you can imagine my thoughts when I went to collect her. After having the car since August I just wanted to get her home and crack on for PV/Summer. So now its set to cost me money again to put it right :(

This time I'm doing it by myself with help from the bodyman as I can't trust anyone else to get it right anymore.

Plug

27-11-07, 04:41 PM

shame to hear the welder F(_)cked you about.

Good luck with the project thou

craig green

27-11-07, 04:43 PM

Could be OK if you make steel panels to cosmetically flush off the inner wings & chassis legs upfront. Its clearly strong enough.

Plug

27-11-07, 04:50 PM

or cover all the welds in filler lol

tom_beverley

27-11-07, 07:16 PM

or cover all the welds in filler lol

No thankyou :roll: Thats what it was like before and look at the mess it made.

I think its very strong now, but theres just so much work to make good. Seriously, for the same amount of time I could put the new inner wings on and be happy in my own mind it is done properly. Its been done too much as a patchwork quilt, the inner wings he had made up are reasonably tidy but its all the plates he has welded on top.

AND having the seams showing looks much nicer IMO

tom_beverley

13-01-08, 12:59 AM

Zero progress since my last post :(

In fact, things are starting to go backwards, after buying many new panels (thanks Steve!) I'd like to confirm that the van will be receiving:

New inner wings
New front panel
New inner wing struts

So basically a new front end :)

This time Mark (eventual bodyman), my dad and myself will be removing all the sh*t and building it back up again properly. Still have to talk my dad round to stitch welding the front end up though as he keeps insisting its not necessary.

So, still sh*tloads to do and no time to do it, I'm skiving now and just having a break from doing my building services coursework lol Seriously though, I am getting worried about making PV already as I know June will be here in a flash, I just hope I can afford to buy everything needed and plan things well enough :tard: I still need to buy:

Powdercoat suspension
Heated windscreen
Fibreglass wide front wings/Modify new GM ones
Corbeau Sprint buckets
Rollcage
Fibreglass bonnet and tailgate
Respray
New wheels (possibly one step too far I think before June)

Peace out

Adam

13-01-08, 11:47 AM

Plenty to do then.

craig green

14-01-08, 10:36 AM

Give it you best shot for PV anyway. Making it to TRAX or another event should be worth it anyway.

Rickyb

26-07-08, 12:12 PM

what happened with this

Welsh Dan

26-07-08, 01:04 PM

I tihnk he bought a new shell.

shy witness

26-07-08, 01:15 PM

aye.

it needed a serious ammount of work.

but fair play to him for having a go at it

DW-Nova

29-07-08, 08:53 PM

whats happened with this project then mate? have you lost intererst? that was a real shame about the welding that was done, when i was looking at the progress pictures i was thinking the welding didnt look very good at all but i thought it was far from finished, if you've given up on the project i know someone who's interested in the engine and box?

tom_beverley

30-07-08, 09:51 AM

Cheers for the comments.

I reluctantly gave up in the end due to the serious amount of work/time it would take and due to uni I sadly don't have. It was sad to see her go but IMO was the best option as it would never had been the pristine example I wanted it to be. If the welding was done to a better standard then who knows, I may of still had it now.

I've since bought another shell which is one of the cleanest I've seen and is completely standard at present. Plans are to basically put the engine and box into this one along with a pukka brake setup. I'm still undecided whether to wide track and arch the new Nova as its just so clean, I need to start a new project thread to show it off!

DW - Sorry, the engine and box aren't for sale.

shy witness

30-07-08, 06:25 PM

good on ya mate.

glad to see your having another go ...with a different shell

tom_beverley

05-11-08, 06:41 PM

Right, about time for an small update as I havent uploaded any of my new pics at the minute... I've decided to carry on with this thread as essentially the new shell will achieve the same end product as I first set out for.

I bought my new Nova from near Cheltenham (some 300 miles away from home) after I spotted it on Ebay in February 2008. It instantly grabbed my attention and tickled my fancy strings so I (much to the seller's annoyance) requested bucket loads of pics of the usual problematic areas - at least I had a crash course on those with the van! The seller (Mike) was very helpful and sent me lots of good quality pictures which boosted my confidence of bidding since I was unwilling to travel the 300 miles to view. So, I whacked my bid in and anxiously refreshed the screen as the timer counted down and much to my relief I won :) My dad was nice enough to take me down as he has a trailer and tow bar so a week later she was home sitting pretty in the unit :D She's a little 1.0l in Gazelle Beige, only done 28,000 miles and is honestly one of the cleanest examples I have seen and countless times better than the van.

Excuse the mess :(

http://img.photobucket.com/albums/v147/tom_beverley/IMGA0235.jpg

http://img.photobucket.com/albums/v147/tom_beverley/IMGA0238.jpg

Unfortunely due to a number of things I hardly did any work on the shell until the Friday before PV 2008. After a good wash, polish and tidy she came up like brand new...

http://img.photobucket.com/albums/v147/tom_beverley/DSC00272.jpg

And here she is at the services on route to PV 2008 next to Iain's 2.0l Ecotec (excuse Emma in her dressing gown lol).

http://img.photobucket.com/albums/v147/tom_beverley/DSC00277.jpg

tom_beverley

05-11-08, 06:53 PM

You can still see the original factory OK stamp in various locations around the car...

http://img.photobucket.com/albums/v147/tom_beverley/DSC00425.jpg

http://img.photobucket.com/albums/v147/tom_beverley/DSC00430.jpg

I think the Waxoyl has helped tremendously!

http://img.photobucket.com/albums/v147/tom_beverley/DSC00428.jpg

http://img.photobucket.com/albums/v147/tom_beverley/DSC00418.jpg

http://img.photobucket.com/albums/v147/tom_beverley/DSC00416.jpg

http://img.photobucket.com/albums/v147/tom_beverley/DSC00412.jpg

scott.parker

05-11-08, 07:02 PM

**** that is clean!

TBH i didnt know you quit the last one,lol

PS: off topic dose that free tv thing in your sig work???? lol

Scott

Mike

05-11-08, 07:05 PM

Fcuk is that what all those stamp's are! There all over my car, i was wondering what they were for lol lol

mayhem

05-11-08, 08:29 PM

to mint to wide arch it. i love it like this

adam c

05-11-08, 09:38 PM

looks very very clean!how much did you pay for it or is it a secret;) ?

iirc you were parked up about 2 cars away at pvs?

BRoadGhost

05-11-08, 10:13 PM

Love the colour

t45_ste

05-11-08, 10:18 PM

Love the colour

:thumb:

Looks minty mint, im sure your going to finish to the standard it deserves:)

almond

06-11-08, 12:38 AM

gutting to start again but in this case well worth it with that new shell

tom_beverley

06-11-08, 09:20 AM

Cheers for the comments :)

Scott, I haven't got one yet but it all depends on how many people use my link and sign up. It usually involves a free trial of somesort, I chose 3 months LoveFilm free and decided to carry on afterwards anyway as its only £3.99 per month.

Adam, I paid £655 for her which was £5 over what I said I was going to bid but I supppose limits are there to be broken (if only just lol). Yeah, I think I remember your Nova a couple up from mine, was very clean too, should have come over for a natter!

Thanks Ste :)

I'm going to disappoint some people here but I'm changing the colour, it was a hard decision with it being rare and original, but its not what I'm after in the end. I'm still sticking with a Vauxhall colour though, albeit it a little more yellow...

The engine bay was stitch welded (very well too, thanks Tony!) with a HH chassis plating kit installed. Using the same technique as Olly (trackdaynova) I prepared the seams by paint stripping them and scraped away any remaining seam sealer. After welding the seams got wire brushed down and given a coat of red oxide type paint (similar to red oxide but provides much better adhesion). The engine bay is now painted to an excellent standard, I just need to polish the lacquer a little more to get a crystal clear finish before the engine goes in. I've got photos but I need to upload them.

craig green

06-11-08, 10:32 AM

Damn that Gazelle Beige shell is nice.

Keep at it Tom, you'll get there in the end with stunning results no doubt.

Rickyb

07-11-08, 05:45 PM

looking good matey shame your van ended up like mine but thats life i serpose. :thumb:

kenny_afh

09-11-08, 07:25 PM

what an improvement the new shell is! definately worthy of its cage :)

tom_beverley

19-04-09, 02:01 AM

Whoa, old thread time lol

Looking to start up again and I'm hoping getting this progress thread going will keep me motivated. After last weeks meet at York Raceway and wandering amongst the cars in the pits my motivation was given a reet boot up the backside. Been quietly collecting parts ready to crack on alas I'm still a few essential ones shy, mainly want some bucket seats so I can get the rails in for the side mounts. There's that many things happening my heads in a bit of a muddle thinking what to get on with next but I'm concentrating (or trying to) on one thing at a time.

First off let me show you my intended brake set-up which I started collecting around a couple of years ago now with a £200 ebay purchase and I've (very slowly) been investigating the most effective yet economic way of creating the complete set-up. Nearly there now but have to pay about twice what the calipers cost me for the brackets and alloy bells to be made up in top spec 7075t ally... watch this space :D

http://img.photobucket.com/albums/v147/tom_beverley/15042009074.jpg

http://img.photobucket.com/albums/v147/tom_beverley/15042009075.jpg

http://img.photobucket.com/albums/v147/tom_beverley/15042009070.jpg

http://img.photobucket.com/albums/v147/tom_beverley/15042009073.jpg

http://img.photobucket.com/albums/v147/tom_beverley/15042009078.jpg

Got a few pics of the engine bay too (still haven't gone over the lacquer yet though) although for some reason no camera can seem to capture the colour properly. Note how thick I am in that the reinforcement plates on the bottom arm legs on the wrong way, not that it should matter - should it? The perfectionist in me wants to grind them off and do them properly.

http://img.photobucket.com/albums/v147/tom_beverley/15042009055.jpg

http://img.photobucket.com/albums/v147/tom_beverley/15042009054.jpg

http://img.photobucket.com/albums/v147/tom_beverley/15042009057.jpg

Leeboo

19-04-09, 02:11 AM

Thats chris astley standard of welding! Top job. That shell was a bargain.

tom_beverley

19-04-09, 02:12 AM

Luckily these came with the calipers too!

http://img.photobucket.com/albums/v147/tom_beverley/15042009081.jpg

Here's a few more pics of the genuine Pilbeam cage I bought from Mark. I'm planning on getting this trial fitted inside then removing it and get it powder coated anthracite which is going to be the interior theme I think to contrast with the yellow.

http://img.photobucket.com/albums/v147/tom_beverley/15042009051.jpg

http://img.photobucket.com/albums/v147/tom_beverley/15042009063.jpg

http://img.photobucket.com/albums/v147/tom_beverley/15042009079.jpg

Bought this to save me cleaning my old one up

http://img.photobucket.com/albums/v147/tom_beverley/15042009064.jpg

Got all this to get through yet lol Theres a few tasty surprises in there too which I'm hoping not to give away until a bit later.

http://img.photobucket.com/albums/v147/tom_beverley/15042009062.jpg

http://img.photobucket.com/albums/v147/tom_beverley/15042009061.jpg

tom_beverley

19-04-09, 02:24 AM

And thinking of improving upon the engine bay already, I think I'd rather get these out and make the scuttle area nice and smooth. Thinking of making a carbon fibre cover for the heater hole but that would require grinding the lip down - more work lol

http://img.photobucket.com/albums/v147/tom_beverley/15042009058.jpg

Few more photos of the engine bay

http://img.photobucket.com/albums/v147/tom_beverley/15042009056.jpg

I need to get in touch with Mark (painter) to sort out the seam sealer along the edge of the scuttle cut and also tidy up where the patch was done near the battery tray (was literally smaller than a pea size hole).

http://img.photobucket.com/albums/v147/tom_beverley/15042009060.jpg

http://img.photobucket.com/albums/v147/tom_beverley/15042009053.jpg

scott.parker

19-04-09, 03:36 AM

Hang on!! have i missed something??? last thing i saw you had a red van??!!

Whats going on?

Scott

tom_beverley

19-04-09, 12:32 PM

Where have you been hiding Scott?

Well, to be fair I haven't really made it all that well known but to cut the story short the van was welded terribly basically ruining the shell so I decided it would be best to start from a much better condition shell in the first place which is when I bought this little gem.

I bought this from Cheltenham in February 2008 so I've had it for over a year now and embarrasingly this is as far as I've got due to other commitments. Working full time and doing a degree part time means I'm pretty busy and when I have time I just want to chill out lol

I'm carrying on keeping it under this thread (need to get admin to remove the van out of the title though) as its essentially going to achieve the same end product. Saying that the spec has been uprated a bit since the start as you do!

tom_beverley

19-04-09, 03:50 PM

Just had a look back through this thread and theres loads to update on

I bought this for a small fee since it had a tooth missing on its input shaft

http://img.photobucket.com/albums/v147/tom_beverley/DSC00182.jpg

http://img.photobucket.com/albums/v147/tom_beverley/DSC00172.jpg

After a phone call to HH I'd bought what I was told is probably the last input shaft available as due to dropping demand were unlikely to get another batch made up. Lets hope I don't break it then lol

http://img.photobucket.com/albums/v147/tom_beverley/DSC00163.jpg

Standard helical cluster removed from the F13 casing

http://img.photobucket.com/albums/v147/tom_beverley/IMGA0242.jpg

I had a crack at installing it myself but didn't get very far as despite following some instructions I couldn't get the input shaft out without a press. Since its an expensive bit of kit I thought best to leave it to the professionals so it went to Easigears in Middlesbrough to be rebuilt, renew all the bearings and have the diff installed as parts of the casing needed machining for it to fit.

http://img.photobucket.com/albums/v147/tom_beverley/DSC00171.jpg

Mmmmmmm, straight cut goodness :D

http://img.photobucket.com/albums/v147/tom_beverley/DSC00259.jpg

4.18FD installed along with the Tran-X limited slip diff

http://img.photobucket.com/albums/v147/tom_beverley/DSC00256.jpg

Adam

19-04-09, 03:54 PM

Looking great!!!!
Nice work.

Want me to remove "van" from the thread title??

tom_beverley

19-04-09, 04:00 PM

Whilst everything was apart I thought I'd clean up inside the bellhousing too

http://img.photobucket.com/albums/v147/tom_beverley/DSC00261.jpg

And started cleaning up the two cover plates as they were pretty grim

http://img.photobucket.com/albums/v147/tom_beverley/DSC00264.jpg

Covers polished up although not sealed at this point

http://img.photobucket.com/albums/v147/tom_beverley/DSC00381.jpg

Casing finished off, I'm not sure wether to get some stainless bolts are just clean and polish the originals up...

http://img.photobucket.com/albums/v147/tom_beverley/IMGP0296.jpg

tom_beverley

19-04-09, 04:01 PM

Looking great!!!!
Nice work.

Want me to remove "van" from the thread title??

Cheers Adam, yeah could you please?

Ta.

Adam

19-04-09, 04:10 PM

Done

tom_beverley

19-04-09, 04:39 PM

Cheers pal.

Along the lines of polishing I've started to polish my T40 inlet (haven't touched it for months now haha) which when I started was a really rough casting. Having trouble with some of the hard to reach areas right in the corners, there must be some sort of tool I can buy to get in there...

Some progress photos

http://img.photobucket.com/albums/v147/tom_beverley/DSC00254.jpg

http://img.photobucket.com/albums/v147/tom_beverley/DSC00255.jpg

Heres my new genuine vauxhall 1.4SR distributor which was sent to H&H Solutions to be re-weighted. This was done because the distributor is set-up for a 70bhp 1.4 engine whereas its going to be used on a 140-150bhp 1.6 engine so the weighting inside needs changing to compensate for this. I lacquered this to so it should stay nice and shiny.

http://img.photobucket.com/albums/v147/tom_beverley/DSC00391.jpg

Thats all I have photos for for the minute, comments welcome.

EDIT - just won these too linky (http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MEWNX:IT&item=300307858670). Ideal for a nice re-trim.

fearless

19-04-09, 05:30 PM

Project looking really good so far - good idea to start again on a solid shell - When I saw your first shell I thought you were a brave man to start to repair that !!!!

I've thought about buying a set of thoses Alcons off the bay but always wondered how a Radial mounted 3 pot fixed caliper works with a floating Disc ??? (330mm as well +++) - Look forward to see how you do it

Dave

tom_beverley

19-04-09, 05:43 PM

Cheers Dave, more stupid than brave in hindsight I think lol

Regarding the Alcons, I've been speaking to John at EARS Motorsport who make up a lot of custom fabricated stuff for WRC cars and the like and he advised the calipers would be mounted via a sliding bracket. Like you say, due to the size the discs would be floating too. I've spoken to a few other people who bought the calipers when they first appeared on eBay some time ago but nobody that I know has managed to get them working and onto a car yet. Hence you see the occasional set come up for sale again.

I've heard some rumours that the JWRC Fiesta's these were designed for didn't use them for long due to some operational issues too but we'll have to see. Expensive way to find out I suppose but I don't see a reason why they wouldn't work properly.

fearless

19-04-09, 06:35 PM

Could never understand how the theory worked - but the lure of the pretty caliper made me think of many ways to cure the problem - looks like you may have a solution :thumb:

I have aquired a set of 4 pot alcon calipers for my nova project - just need to work out how to mount them and what max size disc/bell to use with my 16" alloys :confused:

Who do you recommend for fabricating caliper mounts etc

Dave

tom_beverley

19-04-09, 06:55 PM

Yeah they certainly look lovely, definately made me buy them. Plus their design also allows a smaller than usual wheel to be fitted which was something I was after - hoping to get away with a 16" wheel.

I'm sending mine to be done by EARS Motorsport (details here (http://www.ears.co.uk/motorsport/acatalog/)) shortly, just waiting for John to get back to me. They'll need a full suspension leg including strut, track rod end, hub, carrier and wheel so they can get everything spot on. The calipers apparently suit 300-350mm discs but it was after speaking to John he advised 325-330mm would be better.

If you end up buying some calipers then let me know if you want to go with them for the brackets too as it might save us both a few quid, I'll be getting my ally top hats done by them too...

Cheers.

Jay

19-04-09, 06:58 PM

Another yellow beast! Will this one get finished? lol

tom_beverley

19-04-09, 07:26 PM

Yay, always wanted a yellow Nova :)

I'm pretty sure this will get finished, only a disaster will stop me :wtf:

Whether it will be finished this year or not is the question! lol

Count Vaux Alot

19-04-09, 10:43 PM

Interesting project - i'm not sure if i'm going to get over you changing the colour from beige to yellow though lol

twin40s

20-04-09, 01:47 PM

Are you still going wide arch and wide track. if so what wide track set up are you using thanks.

dj_wudgey

20-04-09, 01:54 PM

good work matey nice project!!

tom_beverley

20-04-09, 01:59 PM

Count, well you better :p Nah, seriously it was a hard decision to make but its for the better IMO. Original colour was awesome, I agree, however this is going to be much nicer IMO and certainly suit the car more.

twin40s, yeah I'm still going wide arch and wide track. The kit I have is from Clark Motorsport (formally Walden Engineering) and consists of fabricated bottom arms, tie bars and brackets, rear beam, steering rack extensions, all of which is fully rosejointed. Seems quite a lot of money for what you get but at the same time you can appreciate the time going into making each kit.

Cheers wudgey!

twin40s

20-04-09, 02:05 PM

excellent mate have you got a number or website for them.

tom_beverley

20-04-09, 02:29 PM

Yeah website can be found here (http://www.clarkmotorsport.net/cart/default.asp?pageid=4) and the phone number is 0133 9885 666. I can't remember the contacts name, sorry.

Count Vaux Alot

20-04-09, 05:15 PM