Project Jeremy

[djshaggeh]

Well here goes..

Base Model a few weeks after i got it:


http://i25.photobucket.com/albums/c57/djshaggeh/DSC00073.jpg
http://i25.photobucket.com/albums/c57/djshaggeh/DSC00207.jpg
Genuine miles.

Until just before christmas I when bought I bought a set of cav GSI rims (cheers ernie:thumb: ) had them refurbed and sprayed and got rid of the lovely sidestrips:



http://i25.photobucket.com/albums/c57/djshaggeh/DSC00182.jpg

I was working as a tyre fitter before christmas and unfortantly i dropped my keys in a customers car and the *******s never came back. With it being a nova I only had one key. Silly me didnt check here to know that there is a code on the bottom of the ignition barrel thier. So i wired in a hidden switch, key, and push start, all maplins specials.

My dodgey wiring caused the interior and engine bay fan not to work, resulting in a very unreliable ride. So over christmas whilst having to drive my sisters superfly ka:cry: i decided its time to get this out my mates garden and put it to use:

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00071-1.jpg

As you can see from the sunshine, I bought the calibra donor car in the summer, my mate stripped it of its xe and weighed in the calibra. The engine has sat in his garden since...

Over christmas I landed a new job at a local parts place (allparts - http://www.allparts-automotive.co.uk) perfect!:thumb: So began buying some tools and booked the 2nd week off in January. I had never had the guts to do this and had always planned to pay someone to do this for me. But after alot of research on this forums I thought "I can do that" and so:

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00205.jpg

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00209-1.jpg
and its out... (if it was only it was as quick and easy as writing this post)
But on a serious note, i dont have alot of tools (breaker bar, hammer, sockets 10-20 and a 30, spanner set, screwdrivers and two trolley jacks) and I managed quite easy. With some help from some friends of course!

Next step: strip out the sound deadening and nitromorez the areas i need to weld. Tommorow or Saturday - keep you all posted.


Taking an Engine out Guide (for those that dont know how to do it, like me up until a couple of hours ago)

Disconnect everything from the engine cable and pipe wise, always good to start with battery (label it if you want)

Radiator out, manifold out, hubs off (I disconnected everything and pulled the hub/driveshaft out from the gearbox as one piece, on both sides)


Take off the anti-roll bar, lower arms and the funky sway bar things on each side.

Disconnect the gearbox linkage by taking out the 'T' style pin, (you'll know what i mean when you see it) undo the bolt that pinches in the arm, get in the car n give the gearstick a wiggle.

Make sure everything is as clear as possible in the engine bay, wires, pipes etc.

Take the weight of the engine with two trolley jacks, one under the gearbox and one under the sump, on the flat bit on the left, use a square of wood. (not recommended: jacking on the sump, however mine was fine)

Undo gearbox mount first (right at the back, under the inlet right at the bottom, tackle it from drivers side front wheelarch) then the left hand side mount and finally the right. Obviously becareful with the last mount as the engine could tip, however mine didnt.

Slowly lower the engine onto three bricks (works well) you might have to lift the front of the car (two man job) and adjust it so the engine is NOT supported in anyway by the car.

Get a couple of mates to either:
Lift the front the car up and roll the car back over the engine or as I did (check the last picture) lift the front end of the car to one side. Leaving the engine on the deck.

When its out you can pick it up with a couple of mates. Hope this helps :thumb:

[vaughanmc]

I quite like that colour, was this not on ebay a week ago...?

[djshaggeh]

nah, i bought it over a year back from some guy near dover. He ran a BMW dealership and traded it in belive it or not?! It was standard when i bought it.

[Riggy]

lol good work , thats just how i did my first engine swap lol , but after a few of them , i went and got a proper crane etc, makes life so much easyier lol

[djshaggeh]

Thanks mate. When i move into a place with a garage i will probobly get a hoist. Picking up the engine on Saturday, gotta try and squeeze it into the back of the sisters ka, whats the chances? slim?

[burgo]

na it will fit lol. good to see you doing what you said you were gonna bud

[Martin]

when i got one of my xe's from Rexy it only just when in the backo fmy uncles veccy

[Nick]

Not much use, but an E16SE definetly fits in a royal mail van ! :)

[burgo]

i got a v6 in the back of this easy enough so a valver will go in a ka

http://www.trustvehicles.com/photos/silverhyundaiamica-02.jpg

[Ernie]

good work fella and thanks for the thumbs up for the wheels.
On the subject of engine's i hade 2 xe's in the boot of my 2.2 diesal civic and a gearbox to 1 side in the back seat area.
I also had chris gsi sat in the front and jen sat in the back.
It drove fine but scraped a few of the speed bumps going out of london.
Oh the joy of a lease car.

[djshaggeh]

i got a v6 in the back of this easy enough so a valver will go in a ka

http://www.trustvehicles.com/photos/silverhyundaiamica-02.jpg

And it still moved?! Still, you got that saloon from wycombe to london to kettering - anythings possible with burgo!lol

[burgo]

yep, im sure baxter has pics somewhere

[djshaggeh]

heres a few more pics from my mates phone, they came out clearer, enjoy:

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00034.jpg

I noticed everyone else has some pic for them in thier engine bay, so i thought it would be rude not to:
http://i25.photobucket.com/albums/c57/djshaggeh/DSC00035.jpg

[djshaggeh]

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00212.jpg

I bought some nitromorez, engine degreasant, and some paintbrushes.
http://i25.photobucket.com/albums/c57/djshaggeh/DSC00211.jpg
I didnt do too much today, just pulled out some sound-deadening and attempted to take off the steering rack. I thought four bolts, undo the knuckle in the car, pop off, job done. Ended up shearing the bolt on the knuckle, however its undone and the steering rack still wont pop out. Any suggestions?

Picking up the engine tommorow, should be fun! Excited and nervous at the sametime - will the ka cope?!

[NOV4_SPORT]

Best of luck mate, just get stuck in and give it ago, sadly no sujestion about the steering rack iam afraid !


iain

[djshaggeh]

camera phone wont let me upload pics. So just some reading today im affraid.

Wokeup. Nitromored the engine bay, well done half of it. Got majority of the sound deadening off. Just got the gash bit that goes round the brake servo left to do. Is it easier to take the brake servo off? Just thinking of when it comes to welding its prob gonna get in the way. If I do need it off, is it mounted on the inside of the bulkhead, behind the glovebox?

Went to my mates place, rolled the ka in the drive. Got out. Got laughed at. God I love driving the ka.....

They finished laughing, we got the engine on a wheelie barrow thing, rolled it up the boot and lifted it straight in. Nice. Steadied it after I got the story about how an engine fell back and went straight through the back window of an escort one of the lads used to have. Throught, its not too bad, this is a ka - smashed back window, one step closer to the scrap man ;) mind you shouldnt think like that, its my sisters!

Got the ka home, just to find that me and my mate didnt have the strength or the light to lift it out the back. So, its staying in the ka tonight. But not after dropping my mate off in it and going to do some shopping! Twin engined ka... no dont go there!

Anyways tommorow ill get some pics up of the xe.
Gotta find out if its coscast or not!

[djshaggeh]

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00214.jpg

[djshaggeh]

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00213.jpg

[Lee]

lol, sounds to me like your having fun.

If the rack is original, it may be a bit stiff to get off. However, you should be able to do all the welding with the rack still on the car. It makes the thing 10 times easier to manuver about as well!

And Miami Blue nova's are the future :)

[djshaggeh]

Enjoying it so much, im planning the next build - my mates red 1.2 mk2, although he doesnt know it yet lol

Lee - Miami Blue eh?! Cheers saved me a search there nice one :thumb: also no more luck with that steering rack. Ill give it another go before next weekend, if not ill get my mate to weld round it.

Glad you like the colour actually. I never used to - she was originally 'Jeremy the gay coloured nova' (my girlfriend is one of those where everything has to have a name - tbh so am i) but after a few months this wore off. So now its just Jeremy - coz of the number plate.

I now need to move the left hand side engine mount and buy a new gearbox mount from Chris Astley?

Some more photos of the wings being preped. Welder and weld artist are coming next Saturday at 3 til 6 to stitch it up and he takes beer as payment - bonus! Hope it doesnt rust before then.

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00218.jpg

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00217.jpg

YEH BABY!

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00215.jpg

One engine, looking... grimey. Its out the back of the ka now, took about 20minutes to get it out but i wont go into detail apart from - Im glad that ka doesnt belong to me lol

Plan to paint up the engine beens as though its out - Black cam cover and some nice detailing on the Vauxhall DOHC 16v bit. Make it look really embossed or 3D if you catch my drift. Watch this space.

Got some help from my mate Adam, he owns a 1978 V8 Mini Clubman. He is currently rebuilding it ready for the summer and shows. So we decided to do some trackdays in the summer - if we had the cash. Heres some pics of his mini from last year.

Enjoy!
http://i25.photobucket.com/albums/c57/djshaggeh/DSC00132.jpg

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00131.jpg

[Lee]

Glad you like the colour actually. I never used to -



The colour's a grower. I bought mine expecting to respray it but i kind of love it now for some strange reason.

The colour prevents rust as well, most miami blue novas ive seen are mint lol

http://img.photobucket.com/albums/v485/DPursey/daxtek/2007_5.jpg

[tony k]

i still cant believe you fitted all that in that car ernie mate especially with two people with you aswell will fit in a as i had one in the back of my birds one

[djshaggeh]

Thats nice mate, even with different colour bumpers and mirrors.

Which leads me on to - would miami blue colour coded gsi bumpers look right, as im very unsure or should i play it safe and spray them black (bearing inmind my alloys are black gloss)


most miami blue novas ive seen are mint

My theory is dents and scratches dont show up very well. Mine has a massive dent on the roof, on the drivers side. So many people look round the car and miss it. It also has a few scratches here and there and theres some primer too. All the bits will get resprayed back to miami blue.

[tony k]

i would paint the bumpers black mate

[djshaggeh]

i still cant believe you fitted all that in that car mate especially with two people with you aswell will fit in a as i had one in the back of my birds one

I only ever had me and another person in the car at once. Both the back seats were down. Although, I did take the missus and the engine to tescos and got a weeks worth of shopping in there too! :thumb:

[Lee]

A mate did a photoshop of mine of a possible colour scheme, it gives some idea of what coded bumpers would look like.

http://img.photobucket.com/albums/v287/Bottlethroddy/Lee_paint.jpg


Also, FYI the colour code is 272 :)

[djshaggeh]

That looks quite nice imo.

Still unsure thought. Im quite fussy with colour coded bumpers i like black and dark blue and thats it, usually.

[burgo]

see told you the engine would fit

[djshaggeh]

you were right mate, plenty of room

[djshaggeh]

Right update:

Firstly, I blocked the drain next to the car with gunk so I was unblocking it when my phone fell out my pocket. So now its drying...

Cleaned up the engine abit.

Welder man didnt come as it was raining :( So I gotta wait another week or two :(

I did purchase some ATE brakes from trackdaynova for a very good price. So they will be on there way. Cheers trackdaynova!

Also when I picked up my engine I found out my mate had taken the steering wheel from the cali too, bonus! So i got that to fit! Its the four spoke jobby.

Currently trying to persuade my mate to drop the 1.4 8v into his red mk2 1.2 merit. He currently has my old matt black astra gte alloys in the first pic of this post and apart from that its standard. He wants to mk1 the front end, lower it and make it into a mk1 SR. Dunno if he will or not...

Advice needed.

I bought the new copy of total vauxhall and noticed that you can buy motorsport hubs and driveshafts for ?120 (LMF). I was orignally gonna fit GTE shafts with Cav 1600 inner cvs. What do you lot recommend, as I have noticed quite a few valver novas on ebay with broken shafts.

And should I change the clutch as the engine is out?

Cheers in advance,

P.S. Drum n Bass set for download, spun by myself last night, enjoy!

http://www.dnbshare.com/download/djs...promo.mp3.html

[Mazz]

Nice project...
I think if you look at the Chris Astley advert in TV he has a special offer on a complete XE kit (shaft's/hubs/mounts etc) which is cheap.

Also have you thought about a plating kit and uprated mounts
http://www.chrisastleymotorsport.com/product_info.php?products_id=36&osCsid=fcfa41e6de1c43f81a06656893e4cc73
http://www.chrisastleymotorsport.com/product_info.php?cPath=22&products_id=45&osCsid=fcfa41e6de1c43f81a06656893e4cc73

[djshaggeh]

I have thought about strengthening plates and uprated mounts but I want this to be my daily runner over the summer at least, maybe longer. So thought It might be a bit unforgiving for road use, am I right or wrong?! I suppose the strengthening kit deffinatly isnt gonna do any harm. Just gonna check out chris astley advert in TV now.

And cheers for the comments :)

[Mazz]

The plating kit will keep the car together for longer, and will be fine for a daily, but the mounts might be a bit much...well worth a plating kit imo..

[djshaggeh]

Right, update:

Pictures speak louder then words and sony k700i's are the tits, dropped my phone down the drain last week and it still works! :D

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00224.jpg

My attempt at an arty farty arch shot. Note the KA in the background, I was slaggin that off earlier on in the thread, now the clutche release bearings fooked! God I love KAs! :mad:

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00223.jpg

I started on the bulkhead, I couldnt find much in way of info on where to weld other then 'Along EVERY seam'. So I just went for it, Only got a few areas left, about another 2 hours work. Loads of seam selent on there and a good job too coz theres not alot of rust, as you see. Still havent got the fookin steering rack out :mad:. My theory is the bolt has snapped but is still in the cut out on the shaft, hence why I cant just pull it out. :tard:

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00222.jpg

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00221.jpg

If I have missed any areas please tell me!

A quick pic of the whole project, you can really see that dent in the roof, any suggestions on how to get it out?

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00220.jpg

A few questions:

Do i, go and rent a welder (?50 a day + some hefty deposit no doubt)?
Wait for a friend to find time and come round with his arc welder?
Or buy this little bad boy?
http://www.screwfix.com/prods/79434/Power-Tools/Welding/100-No-Gas-MIG-Welder

Cheers in advance and thanks for reading! :thumb:

[Lee]

If I have missed any areas please tell me!


It seems youve missed the engine mount pal :) Good work so far though.

[djshaggeh]

Thanks lee. I take it your on about the driverside mount? I delibrately left it as I was gonna cut it off and move it down. Just trying to figure out the best way about doing it.

[burgo]

spot weld drill bit and drill it off properly

[djshaggeh]

Cheers burgo :thumb:

Hows the saloon?

[burgo]

its being a good trusty work horse ;)
http://i12.photobucket.com/albums/a226/sclurgess/S7300077.jpg

[djshaggeh]

Good to see it went to a good home.

^I forgot how mint it was inside!

[Lee]

Thanks lee. I take it your on about the driverside mount? I delibrately left it as I was gonna cut it off and move it down. Just trying to figure out the best way about doing it.

Adaptor mounts are cheap enough now to warrant not bothering with it. Also you'd have the scope to put a smallblock back in again if you ever needed to.

[djshaggeh]

Right, Ive instructed the missus to ring Mr Astley in the morning.

Getting 2.0 fitting kit and the arb lowering blocks, considered the plating kit and the strut tops but decided against. Reasons, firstly I want this project to be cheap and I'd rather put the cash towards a mig welder.

[Lee]

Right, Ive instructed the missus to ring Mr Astley in the morning.

Getting 2.0 fitting kit and the arb lowering blocks, considered the plating kit and the strut tops but decided against. Reasons, firstly I want this project to be cheap and I'd rather put the cash towards a mig welder.

Good man, personally i dont believe the plating kit is at all needed on a road going car, be it track or road (unless you start running uber powered LETs or are planning on some stage rallies!)

[paulshears]

great colour

[djshaggeh]

Right, the missus spoke to Mr Astely today and the conversion parts should be with me Wednesday latest! Excellent stuff!

Cant wait to drive it, so come the weekend I'll be covered in welding burns.

Cheers for the comments guys!

[djshaggeh]

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00225.jpg

All the bits arrived today! Thanks too Mr Astley! Now I gotta figure out how they fit.

[burgo]

does this help?

http://www.chrisastleymotorsport.com/forums/showthread.php?t=114

[djshaggeh]

Yes, spot on!

Cheers mate.

[djshaggeh]

Right, with help from burgo I modified/strengthend the gearbox mount. Im gonna head up to screw fix tommorow and buy a mig welder.

Been spending too much time at the pub and not enough time on the car, so tommorow I will be welding up that bay!

Heres some pics of the engine mount...

Without Chris Astley kit - you can see the areas I carefully and very accuratly chopped out with an angle grinder!

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00228.jpg

And with the kit. No nuts - dunno if these are supposed to be supplied or am I being silly and it just bolts straight to the chassis?

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00229.jpg

[Rickyb]

top work mate :thumb:

[djshaggeh]

top work mate :thumb:

I wish I could say the same about my welding;

So heres the story.

Went to screwfix on Sunday and picked up a super cheapy bottom of the barrle mig welder (?99) and some same quality mask and gloves.

Got home, unpacked the welder and set it all up. After spending half the afternoon **** arsing around with the wire feed, we began to weld the nova.

The mask was cheap so I opted for the 'mask is for pussys' way of working (big mistake). After about three hours of 'welding' - I say welding, looks more like its being attacked by a flock of pigeons. We even named one weld 'I heard it on the grapevine' lol (pics to follow - if im not too ashamed!). It got dark so we retired for the evening or so I thought.

Got to about 9 o'clock and the old eyes started to itch and hurt so I lay down and tried to sleep it off. I woke up after about an hour to find that I couldnt open them as the pain was bad and they were watering bad. So I got up and went to A&E. I got seen to around about 11.30 and they squirted some liquid cocaine (or thats what I told myself!) into my eyes and they began to numb. Matey poked around a little piece and I went home to sleep. Woke up and they are just as bad. So I went to the hospital again. Got em checked up and they are healing alot better now.

So in a summery:

2x trip to A&E + 1 hefty dosage of arc eye = 1 day off: seeing everyones face as red dye dribbles out of your nose and eyes, priceless!

and

Always buy a decent mask (and make sure you wear it)

[djshaggeh]

laugh as much as you want, we all did!

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00232.jpg

Introducing, 'I heard it through the grapevine'!

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00233.jpg

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00234.jpg

Enjoy! :thumb:

[Martin]

LMFAO 1st welders flash is ace(not) had ot about 10times now.. and i can tell you this..it dopesnt get anybetter lol..


welding not to bad for a 1st go..

[clarke frazer]

not the worst welding ive seen lol better than mine tho hopr the eyes get better it wrecks so sore

[Adam]

LMAO @ just welding without a mask lol lol

Welding doesn't look bad for a beginner. Tho from the pics, id say penetration doesn't look 100%, might need more ampage/move the torch more slowly.

[djshaggeh]

I thought the same to be honest, the welds on the inner wings/turret tops seem to have good peneration as you can probobly see in the pic. Also checking inside the wheel arch and there is some penetration.

However the rest of the welds seem to have settled on the surface, I cannot turn up the ampage on the welder as it is bargain basement. It only has wire feed speed and a 10% duty cycle and 15% duty cycle button. Seems to weld the best on a slow wire feed and on 10% duty cycle. You recon that holding the torch abit further away it will penetrate better?

Gonna clean up the welds/redo the weak ones next weekend and I think this time Ill use my mask!

Eyes are alot better just got misty vision now - cheers for the conern!

Picking up the ka tommorow and parting with ?360 - ****ing fords.

[Martin]

I thought the same to be honest, the welds on the inner wings/turret tops seem to have good peneration as you can probobly see in the pic. Also checking inside the wheel arch and there is some penetration.

However the rest of the welds seem to have settled on the surface, I cannot turn up the ampage on the welder as it is bargain basement. It only has wire feed speed and a 10% duty cycle and 15% duty cycle button. Seems to weld the best on a slow wire feed and on 10% duty cycle. You recon that holding the torch abit further away it will penetrate better?

Gonna clean up the welds/redo the weak ones next weekend and I think this time Ill use my mask!

Eyes are alot better just got misty vision now - cheers for the conern!

Picking up the ka tommorow and parting with ?360 - ****ing fords.

slower speeds and not to far away, you need all gas you can get..

[belly257]

good project mate

[djshaggeh]

Thanks for all the comments :thumb:

I cant wait for the weekend to get back out there and clean off all the **** welds and redo them plus do the rest, should be fun. I have a friends dad coming down, he is a welder by trade so is going to give me some pointers.

Im lucky enough to have a really good paintshop at the end of the road so I will have to enquire about some paint in the next comming weeks. Im not fortunate enough to own a garage or a compressor so it will be done with rattle cans. Im pretty much decided that I will keep the engine bay the same colour of the car (miami blue).

I get the keys back to the ka when my friend returns home from work. Im almost tempted in going for a drive coz I havent driven in weeks.

Second thoughts I need to finish the nova...

[Lee]

Arc Eye is the pits, had it a few times and it hurts muchly. But still not as much as petrol at 3.0 bar squirting into them lol

[djshaggeh]

I used to work in a sheet metal factory and one of the welders had arc eye and I thought to myself dont look too bad I can deal with that, Im hardcore. Well I aint, and yes if hurt like buggery and I was worried that it wouldnt improve. Never again!

[djshaggeh]

Right plans for tommorow -

Reweld the kak welds
Drill out front mount and reweld it further down
Seam seal and primer, hopefully

If everything goes to plan I will try and mount the engine on sunday.

[djshaggeh]

Right, done some work at the weekend, not as much as I hoped but nevermind. Ran out of funds so proper skint til a week on Friday, boo :(

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00235.jpg

I finished off the welding. Looks pro.... not! Infact I'd go as far as to say it looks like a right fookin mess. Nevermind Ill put it down to experience or lack of it!

Seam-sealed it with the brush on stuff, gives a really nice finish (sarcasm) looks kind of like astro turf.

I smashed the **** out of the inner wing to allow room for the timing belt on the XE. IS THIS ENOUGH ROOM, comments please?

And finally, just had enough pennys to buy a small can of primer so I quickly roger the bodgered over the top.

All in all I have got stuff done, just looks like Steve Wonder has done all the work.

[Rich]

Im not certain, but i think you will need more clearance, especially if you arent using solid engine mounts. Remember you are also gonna need to change the alternator belt at some point, i would cut a box section and weld it up mate. Might as well do it in these stages instead of trying to fit the engine to find it wont go

[djshaggeh]

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00236.jpg

I bought some right angle over the weekend but was lazy and didnt do any work. I marked out the section I'm going to cut out, Im planning to have a 1 1/2 - 2 cm recess, will this be enough? I WILL get out there next weekend and get the engine bay ready to take the 16v. :thumb:

[djshaggeh]

Right, I got out there and done some work today. I got the welder out and the angle grinder and me and my mate taf set about to do some damage. We cut a hole in the drivers side inner wing and began to patch it up. I let taf do the welding this time for fear of arc eye :) and the end result was this:

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00239.jpg

Once again, some pro welding so a healthly dose of seam sealer soon sorted that out! I hope there is enough clearence?

The cutting and welding took us leass time then we thought so we moved on to the engine. First of all we decided to figure out how these Astley mounts mate to the xe.

Clever me was convinced Mr Astley had forgot to put in three bolts that would used for the gearbox mount. Oh how wrong I was! Just to double check - this is right? (i.e the two plates are on the right side)

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00241.jpg

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00242.jpg

We moved on to the drivers side mount. I started to remove the standard nova mount from the rubber but was unable to undo the bolts at the same time as holding the mount. I dont have a vice, so we parked the Ka on top of the metal part and undone the rubber. From then on it was pretty straight forward and ends up looking like this:

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00240.jpg

Comments welcome,

[Rich]

Dont wanna put a downer on you but i think the box section needs to be higher and travel further back. I made the same mistake first time around on my and had to cut it all out again.

edit-http://i124.photobucket.com/albums/p24/novarich/Image1.jpg

You need the extra space for the pully to be moved for tightening the v belt. Also take into consideration how much the engine will move. I cut mine around where the blue line is, the top of the cutout was left open so the back of the box section was flat level with the strut. The red mark is where the pully actually sat on mine (from what i can remember)

[djshaggeh]

Cheers Richie, much appreciated :)

Looks like we're gonna have to go for round 2 if the weather improves!

[djshaggeh]

I got some paint made up, miami blue code 17L?! and sprayed the engine bay on saturday. I then met a guy that lives local that drives a skyline and runs a bodyshop. He tooking me out last night for some midnight drifting and I gotta say, i certainly enjoyed it, so much so that the next car really has to be an S12 or an S13. Definatetly RWD.

I woke up this morning and pissed half the day away. When we finally got out to do some work I we only got so far and we had to stop due to lack of man power/engine hoist. I gave the boys a call and they came down to help. We got this far before I had to go and do my radio set. However I did get the offer of an engine hoist next weekend, so that should do the trick.

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00248.jpg

[jimbob-mcgrew]

it canne take it capt !!

[burgo]

you keep saying about getting arc eye and therefore letting your mate weld.....do you not have a mask??

[djshaggeh]

yes as the posts reads.

Mask is poop hence why i didnt use it. Nevermind job done. Old news

[djshaggeh]

So I had a day off today to get some work done. After a few hours and alot of stressing about the engine and or car falling we had it mounted.

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00252.jpg

Yeh baby!

I forgot to bend the clutch cable exit :( So it looks like we are re-routing the clutch cable. I also forgot to pull the PAS pulley off the crank so it looks like Ill have to do that next weekend. Apart from that, the clearence for the alternator belt looks ok.

I have an issue with the passenger side mount. I cant remember exactly how to rebuild the mount. I have it bolted to the XE side, put the rubber bush in and bolted that in. Its the bolt that runs through it all. I dont have enough clearance to stick a nut on the back as the gearbox is in the way.

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00253.jpg

[jimbob-mcgrew]

take it !!!!!!!!!

[jimbob-mcgrew]

need help please peeps, gearbox wedged against body, any ideas why ?

[Rich]

I had to put washers between the mount/gearbox to space the box away from the mount when i did mine. Cut dow the end of the bolt so i could get the nut onto it. Was still a very tight fit though

[djshaggeh]

Excellent stuff mate, once again Richie to the rescue!

We (me and Jimbob) had a quick tinker after work. Jimbob slackened off the back mount and we found there is a little bit of adjustment, this helped. We also discussed spacing it, so this looks like the way forward.

We also started on the exhaust, jesus the manifold is l o n g. So we decided the best approach would be to to cut the centre section, mate the cut bit of centre section to the manifold and refit the manifold to the engine. Then chop some more off the centre section and weld it.

Pikey tool co.
Saliva = free WD40
2x paintpots = workbench
ford ka = vice

[KITT1972]

on the gearbox you are also going to need to cut the lug of the gearbox or you wont get the tie rod arm on

[djshaggeh]

Cheers kitt, do you reacon you could mark it on that pic using paint?

[djshaggeh]

http://www.corsa-novatuning.nl/uk/PartsA.htm

There is a couple pics here about 3/4s of the way down. Will an angle grinder suffice?

[jimbob-mcgrew]

omg.. the thickness of that steel !, my poor grinders not gonna like the look of that, he'll give it his all tho, and die for his country if need be, a true warrior.

[djshaggeh]

Right engine cams removed and 2 of the three bolts on the engine mount have been spaced and the bolt has been cut down. The bolt needs another couple of threads taking off but that will be done tommorow. All work curtosy of Jimbob. Cheers dude.

Tommorow we cut down the engine mount bolt and try and deal with the PAS pulley. Maybe sort out the gearlinkage.

[Nobby]

fookin brillant mate i have 2 miaimi blue novas 1 with a xe one with a 1.2 lol im going to reshell my xe after pv and this thread has answered most of my questions lol heres mine - http://i27.tinypic.com/aexjwx.jpg
http://i28.tinypic.com/2vjvdsl.jpg
http://i31.tinypic.com/wqpvkl.jpg

[djshaggeh]

Looks ace, i LOVE the steelies! Makes it a true sleeper!

The future is bright, the future is miami blue!

When your reshelling make sure you give the inner wing a good beating, as my alternator is still too close. I CBA to take the engine out so we decided to cut a rectangle hole through the outer and inner wing! YEHAAAWWW!

[Nobby]

Looks ace, i LOVE the steelies! Makes it a true sleeper!

The future is bright, the future is miami blue!

When your reshelling make sure you give the inner wing a good beating, as my alternator is still too close. I CBA to take the engine out so we decided to cut a rectangle hole through the outer and inner wing! YEHAAAWWW!

yeah it is lol ive treated it to some cesaros now though you can see the big brakes gives things away a little hehe, ye im going to try and cut mine and reweld it i have the xe shell as a pattern though ;) keep the work up chap!

[djshaggeh]

ye im going to try and cut mine and reweld it i have the xe shell as a pattern though

It would have been nice to have a ganders at another xe nova in the flesh first to get an idea of where to cut nevermind its all trial and error this end :)

Scrapped the idea of chopping the wing and decided to take off the inlet manifold and atlernator. We also undid the front mount and rocked the engine forward giving us enough room to get at the inner wing with a club hammer. Taking off the inlet was hassles so as you can imagine that wing got beats. Now I gotta patch up the holes I been cutting in the wing.

I gotta get a new pipe sorted and fitted (the one below the inlet) and get the inlet back on and then HOPEFULLY we will be back on track.

Oh and I got brand new nova GTE shafts and Cav 1.6 mk2 inner CVs. Discs and pads. Just need an injection fuel tank.

[djshaggeh]

Today Jim-bob cut off the PAS pulley and we cleaned up the inner wing ready for welding.

I also set to work cleaning up the rocker cover as I cant resist painting it black and getting the spark plug cover looking abit more respectable (thanks to a friend) watch this space.

We disscussed removing the oil cooler and Jim set to work and removed both filters from the XE and the 8v. He then removed the sandwich plate from the XE. We were left with these bits:

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00257.jpg

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00258.jpg

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00259.jpg

Can anyone enlighten us?

[trackdaynova]

What do you need enlightening with Shag?

The first pic of the block has a bypass fitted, which mean you cannot run a sandwich plate with that bypass fitted

The second pic of the block means you can fit the sandwich plate directly into the thread.

Is that what you wanted to know?

Hope this helps

[djshaggeh]

Do we need to fit the thread from the 8v engine to the 16v engine so we can get rid of the sandwich plate and the oil cooler all together?

Sorry I didnt explain that very well

[trackdaynova]

Yes, if you want to get rid of the cooler altogeher, you need to remove the bypass thread out of the 8v block, using a 10mm allen key, and screwing it into your 16v block.

Then simply screw on your oil filter itself

Hope this helps

Olly

[djshaggeh]

Once again cheers. We couldnt see the allen key bit, I guess you just unscrew it with a 10mm allen key down the centre of the hole.

Ill buy a new filter at work, along with an alternator belt.

Then Ill have to go to vauxhall and order the funky three way pipe which sits on the back of the block under the inlet manifold. Then, just then. I might be able to start refitting everything...

[trackdaynova]

Yep - you've got it, the allen key hole is in the centre of the thread :)

Let us know how it goes, upon refitting the bypass, be sure not to overtighten it and crack your block, and you won't need any sealant of any kind - just put it in dry.

Happy to help.

[djshaggeh]

We got the thread out of the old 8v just using a rag and gripped with hands came off real easy in the end. There wasnt an allen key bolt so maybe some have and some havent?

We got out there yesterday and got a fair bit done. When I say we I mean Jim-Bob aka my mate taf and I just was really there for moral support!

We started by building the driveshafts. I bought brand new nova GTE shafts and replaced the inner CV joints with Cav Mk2 1.6 inners. Firstly we only made the passenger side up and fitted it. Everything went good until we put the hub on and the lower arm and the tie bar in. We couldnt get the pin for the lower arm into the hole on the bottom of the hub. So out came the hammer and after a few hits we realized the driveshaft wasnt all the way into the gearbox. So the only problem now is the hole for the split pin needs redrilling as its too far away from the hub nut. Or I supposed I could space the hubs out a lil bit?!

We put the radiator in but couldnt get the fan in. So f00k knows how the fan and the manifold is going to sit in that tiny gap.

Taf done his pro welding skills and unleashed the dragon on the inner wing. Now it looks fairly sturdy. We stonechipped it and went on to clear a little more room for the alternator.

Things were moving fairly quickly until I woke up this morning and decided that today would be spent on the xbox 360 due to rain. F00kin weather! Why cant they release GTA4 already!

Heres some pics:
http://i25.photobucket.com/albums/c57/djshaggeh/DSC00265.jpg

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00266.jpg

I also decided to scrap the idea of painting the engine up. Im gonna leave it looking scrappy and horrid just the way I like it ;)

P.S Cheers trackday for the calipers!

[Ernie]

Glad to see it's all coming together bud.
As for the clutch cable ive noticed that you aint fitted the inlet manafold yet so you should be able to bend it with an exstention bar and bend it down to the passenger side.

[djshaggeh]

I did give it some, but not enough! The pipe bit on the end just started to oval. We thought about angle grinding it down and at an angle, so it points down and towords the passenger side. Inlet wont being going back on for a few days coz I need to replace the three way pipe that sits below the inlet. We stuggled for too long to pull the ******* off, so it got cut. Wish we hadnt now coz I have to go to vauxhall for a replacement.

[djshaggeh]

I had the day off today so I thought I'd be cheeky and get some work done. I didnt do alot but its moving along nicely atm. I trimmed the clutch cable exit on the bulkhead and Im nearly satisfide that its pointing down towards the passenger side of the car, might need a little more trimming but well see.

We were getting pretty pissed off with our selves for leaving loads of junk under the car (i.e nuts blots and washers) so we decided to get it back together to get it moved and have a general clear out. It also meant I could finally see how the car would sit with the XE.

After plenty of jimmying with the axel stands and a trolley jack this is how it looks. The pics dont really do it justice but it is LOW!

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00272.jpg

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00270.jpg

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00269.jpg

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00271.jpg

[vauxestate]

nice mate an its also answered alot of my Q's lol

[djshaggeh]

Good stuff!

Check out trackdays project his one in the earlier stages really helped me out. Such a lovely car too.

[burgo]

wheels look the tits

[Steve]

Just read the whole thread mate, good work! Makes me wish i'd given my conversion ago myself.

Sounded pretty harsh about the arc eye but live and learn, glad to see you've nearly finished it now. Quick question - what suspension you got on there?

[djshaggeh]

At the min, its got apex springs (40mm) allround.
Apex shocks on the front and billstein shocks on the rear.

It looks real low at the back because its got a load a sh!t in the back of the car.

[djshaggeh]

wheels look the tits

Cheers burgo, I bought them off ernie for £50, I gave them a quick style refurb whilst I was working as a tyre fitter and luckly one of the chaps we did alot of work for decided to spray them up for me for free! Bonus!

[djshaggeh]

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00273.jpg

The first time in a good few month that old Jeremy has moved.

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00274.jpg

We put the bonnet on and got abit closer to putting the clutch cable back in. The section that runs through the bulkhead needs a little bit more chopping and angling so it points in the right direction. Ive also sourced a GTE tank which I plan to pick up at the end of the month. I also need some brake pipe union nuts.

[djshaggeh]

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00273-1.jpg

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00274-1.jpg

[djshaggeh]

^woah doesnt look like theres alot of clearence in that shot coz I took it from a retarded angle.

Anyways.
Me and Jim-bob have been pottering about for the past week in preperation of my pay-day. I got some bits sorted and got some items I needed through the post.

Pay-day Wednesday!

[djshaggeh]

I picked up the fueltank (cheers chimp) and my bits from vauxhall and plodded on. Its been 1 step forward, two steps back for a while now so I was determinded to get something done.

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00289.jpg

Jim-Bob came round to swap over his gearbox, so I thought Id take a photo.

[djshaggeh]

Whilst Jim-bob changed his gearbox, I got on with some wiring.

Armed with the girl friends laptop and a pair of wire strippers I began. I was using the diagram from the articals section. I kinda started at the bottom, wiring the nova loom to the XE, ie the alternator and oil sensor.

I noticed that one of the sensor at the front for the sump had been damaged. The wires had pulled out of the terminals.

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00290.jpg

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00291.jpg

[djshaggeh]

Jim-bob is gonna repair the sensor.

The next step was the fueltank. It already had a pump :thumb:
Unfortunatly I bought the wrong size fuel line so I need to get that sorted. Appart from that everything else was in place.

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00294.jpg

[djshaggeh]

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00293.jpg

When we pulled that sensor out we thought the sump had been drained.

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00295.jpg

Whilst wiring up the ICV (idle control valve) I noticed on the same loom, there is a blue wire with a spade style conector, where does this go?

Cheers for looking

[Lee]

That would be for the water temp feed for the dials on the donor car. You dont use this, you shoud be using the one on the nova loom :)

Make sure you fit the alternator before you put the inlet on!

[Jack]

Make sure you fit the alternator before you put the inlet on!
lol

[djshaggeh]

I know, I forgot!

If your pro you can do it from under the car, shame I'm not pro! So it looks like it may have to come off in the near future.

[Lee]

I know, I forgot!

If your pro you can do it from under the car, shame I'm not pro! So it looks like it may have to come off in the near future.

lol

Its doeable, but you have to have the driveshaft out, remove the track rod and hold it up out of the way on full lock to the right. And using 2 pairs of hands.

Hear that Jack, he rekon's we're PRO'S lol

[jimbob-mcgrew]

whats the best way to route the new petrol line ?
i was thinking leave the orgional feed line in place, and cable tie the new one straight to it, along the line and up into the bay, sound ok ?

[djshaggeh]

lol

Everyones looks pro compared to me and jim-bobs build, we must be on bodge number 342 by now.

Im even considering getting a private plate, YE H4W or something

[djshaggeh]

So the inlet came off *again* getting pretty speedy at taking it off and putting it back on. Was a good job too because I hadnt wired the alternator up properly. So we resolved that.

Whilst the manifold was off I chopped a dirty great hole in the bulkhead for the airbox.

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00312.jpg

I took a quick photo of the alternator for clearence. Althought the photo is a bit dark.

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00313.jpg

We cut the hole in the bulkhead and began wiring it all up. I rigged in a push button start and a key switch because I got rid of the ignition barrel after I lost my keys - only to find them a couple of months later dangling on the underside of a chair in the living room. Im gonna have a secret kill switch too.

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00311.jpg

Gwan Jimbob!

So close, just missing that fuelline, I ordered 10mm as 8mm does fit over the pump :)

http://s25.photobucket.com/albums/c57/djshaggeh/?action=view&current=MOV00310.flv
Just a little teaser, hopefully get it fired up when I get this fuel line.

EDIT: the sound doesnt work on the vid - ACTUALLY IT DOES I JUST HAD MY SPEAKERS OFF :)

[djshaggeh]

So close, just missing that fuelline, I ordered 10mm as 8mm does fit over the pump :)


Finally worked it out, im after pipe not hose

[djshaggeh]

Whoa, its been a while - so I thought Id update my thread seen as though I havent anything to do - Im a bum/hobo now. I had a bit of a bad week - lost my job due to an arguement at work with a guy in a suit. Nevermind Im sure ill find something else - ANYWAYS!

http://i25.photobucket.com/albums/c57/djshaggeh/DSC00328.jpg
Taf loves wireless :)


So we got the Fuel in and Fuel out sorted. So i wired in my push button start and key switch as I lost my keys a good few months back. Connected up the battery and gave it a start...

It fired up and ran for a few seconds, until we noticed there was a slight fuel leak. So we turned it off and fixed the leak - then we tired again and nothing. Turns out there was a dodgey solder on the wire to the fuel pump so that got fixed. Fired her up again - nothing.

http://s25.photobucket.com/albums/c57/djshaggeh/?action=view&current=MOV00331.flv

So back to the forums - after a few days research/deliberation/testing. We came to the conclusion that its either fuel pump, FPR or injectors. So yesterday me and Jimbob aka Taf took a look at the fuelrail, FPR and injectors.

We pulled out the injectors to see if they were blocked or anything and we were going to test them. They looked good however we still dont know for sure if they are working as we couldnt think of a safe way of testing them.

I ordered a new FPR cost me £47.50 from germany. Its a 3 bar FPR same as the one that came off. The injectors are cream, I was expecting blue as its a 3 bar system - can anyone enlighten me?

So now im waiting on the FPR, im sure it will come today. Hopefully I can slap it on and it will fire up but probobly not - fukin cars!

[big gra]

loks good, helps to have a wireless laptop with a wireing diagram right in front of ya!!

[djshaggeh]

Yes it was very helpful, saved me having to draw out the wiring diagram as I dont have a printer.

[djshaggeh]

So the FPR arrived, we rebuilt the fuelrail and slapped the FPR on and gave it a crank...

http://s25.photobucket.com/albums/c57/djshaggeh/?action=view&current=MOV00341.flv

ITS ALIVE!!! :) :eek: :) :eek: :)

About time too, just in time to re-kidle the love of novas - I started to get really really fed up.

Special thanks to the one they call Jim-bob aka Taf and Lee - forum admin.

:thumb:

[jimbob-mcgrew]

yuh! - taken a while and many bodges, but it fires up and runs fairly smooth considering its not got an exhaust and airbox, should be a beast whens its ready.

[djshaggeh]

Right, the exhaust is on - but its blowing like a b!tch. It needs a re-shape it should do to get me to an exhaust place so I can heat it up and shape it. Heres a video - unfortantly my mate is revving his veccy in the background.

http://s25.photobucket.com/albums/c57/djshaggeh/?action=view&current=MOV00343.flv

Things left to do to get it back on the road:
Re-adjust the gear (boh) selecter
Replace a wheel cylinder
Get/Repair the induction hose from the AFM to the airbox above the throttle body
Get induction hose from airbox to AFM
Get airbox/air filter - any recommendations?

EDIT: Heart attack as jimbob got the throttle cable trapped at a good 6k revs - fortunatly we managed to get it turned off pretty sharpish! ADRENALINE!

[djshaggeh]

Insured today, awaiting documentation to tax it.

Insurence:
6 points
all mods declared
insured for 1500
24 years old
1 years no claims

850 quid third party

Things left to do to get it back on the road:
Airfilter
Get the engine running sweet - at the moment its running very rich, I think it has something to do with the temperature guage not working and the engine thinks its very cold.

[djshaggeh]

^Right that quote only had 3 points. doh!

So it up to 1315 quid, with everything declared (a first for me)!

V5 was updated and sent off a week ago, just awating that and I can drive it. So looking forward to it! I have never been in a xe nova or driven one so it should be fun...

Still got a few finishing touches to do;

I need a throttle cable, air-filter and I need to stop the exhuast blowing.

I plan to drive it to my work (about a half mile) with no tax (what do you lot think) and keep it there and continue the repairs.

[jimbob-mcgrew]

be allright man, take it at a busy time of day and keep the revs low so u stay quiet, others wont agree with the blaggage tho

on the air filter front, i spotted some cheap and nasty universal cone filters in the argos catalogue for £20

[Ernie]

Ive got a spare filter.
Drop me a pm and could prob sort some thing out fella.
Well done with the build.

[that farmer]

oi thats my car!

[Rickyb]

hmm hows this car now?

[djshaggeh]

Unfortunately it got broken for spares as I couldn't afford to run it. I now own a GTE and sold the engine and shell to a couple of mates. ^That Farmer - now owns the shell and is currently giving it a revamp with added extras. Which I'll get him to upload night.