Benn's on going build

[The Simps]

don't you dare! you spend far too much time cleaning it as it is!!

[Benn]

lol Cars need to be clean, i dont like driving my work van when its dirty..lol

[~~joycey~~]

Cant belive that rust mate! :( Did'nt ever exspect to see rust on your car tbh

[Riggy]

awsome benn , the long boring jobs always give more satisfaction when ther done though :thumb:

[Benn]

Cant belive that rust mate! :( Did'nt ever exspect to see rust on your car tbh

Thats seamsealer for you, its good and bad, can keep rust at bay and can allso hide it and help it grow.



awsome benn , the long boring jobs always give more satisfaction when ther done though :thumb:

Yeah hopefully will look all nice when its bodycolour in the arches. Cheers dude.

[Benn]

Christ what a weekend.

So have been thinking about engines and havent been able to make mine mine up, do i use my xe as its a sweet running and quiet as a mouse, find a 1.8 8v and twin carb it up, find a let..
When i get sent a ebay link for a let few days to go, sitting at 900. It sells then get relisted the next day due to time waisters, http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MEWAX:IT&item=300292044141 So a sat here looking at the ad and thought why not txt him a cash offer and see what he says. So i did, he txted back and said yes... Win.

Wad, ready to be spent..
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4679.jpg

http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4681.jpg

So off we set, had hardly any sleep, but the nice cold morning sorts that out..
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4682.jpg

I found that not even 30miles up the road and they still have deep snow, was so unfair!
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_7080.jpg

Anyway lots of driving later we pasted the Vauxhall plant in Luton, we end up in a small town called Olney to view this let.
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_7085.jpg

[Benn]

After following matey to his garage and watching him get stuck inthe snow, then sit with the engine on the limiter trying to get out of it.
He shows us the serecty to stop anyone getting in the garage.. Silver one drags the gold one out of way with seat belt..

http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_7089.jpg

http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_7090.jpg

Benn looking at said let,
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_7092.jpg

A very full garage.
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_7091.jpg

Did all the checks you guys said, big thanks for that! Finding them all ok i handed over 700 and started loading the car.
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4687.jpg

[Benn]

On the way up the radio didnt have much on it, so my dad read to me, which i have to say was nice, and then all the way home too..
Read me this...
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4714.jpg

My dad/ co-poilet/ story reader..lol Thank you, you're a legend as allways.
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_7097.jpg

Nice snow coverd back grounds from the M1..
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4690.jpg

When we stoped for lunch,
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4694.jpg

Bought me a whimpey! God i love their bugers! Time we stoped at, then saw the mk3 cav owners club....
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_7096.jpg

[Benn]

Finely home at. With a slammed vectra...
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_7098.jpg

Back at home.
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4696.jpg

After doing a nice trip of.
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4695.jpg

With a boot full of...
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4697.jpg

http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4698.jpg

http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4712.jpg

[Benn]

Sc legendray hoist.
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4699.jpg

New luk clutch that will go up for sale..
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4700.jpg

Eeewww i dont think so.
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4701.jpg

The blower..
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4702.jpg

Should it have a the slight bend? Check that it moves, does but is stiff, is that good or bad?
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4703.jpg

What should be on this?
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4710.jpg

Can you get new ones of these? As they've seen better days.
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4711.jpg

Sooooooooooo now i just need to get a few bits and do some stripping, sanding, painting, polishing then i can fit it...
Whats the easiest less cutting fmic i can use behind a uncut gsi front bumper?

Gen me up.

[edens-xe]

looks like you got a good buy there benn, did it not come with the f28??
well at least now you wont have to make too many mods to the beast:thumb:
and you dont have to go woooooshtiiissssss every time you change gearlol:D

edit durrrrrr just seen the vectra boot picslol.

[edens-xe]

no that actuator isnt supposed to be bent,and it looks like your gonna need a new water feed pipe to the turbo aswell. is that wire which has been bodged the lamda sensor??? if so i have a spanking new one here for you if you want it??? ims ure we could do a deal lol


oh and if you want any pics or need a look on my let i'll pop over and you can have a mooch

[John]

Wow, excellent stuff benn! Rich has an intercooler and some very nice pipework for sale too, might be worth pming him. Hmmm, i will but a let oneday!

[Benn]

Pauls told me the actuator rod should be ok.. the two pipes will be replaced while getting hidden.
No f28 ed, space f20 to be sold tho..lol

The lambda will be replaced too.

I want a ic that will fit behind the gsi bumper john, with the less cutted poss...

[John]

Pauls told me the actuator rod should be ok.. the two pipes will be replaced while getting hidden.
No f28 ed, space f20 to be sold tho..lol

The lambda will be replaced too.

I want a ic that will fit behind the gsi bumper john, with the less cutted poss...

have a look at rich's for sale threads, iirc he used a frontera intercooler, that fits quite nicely, he did have to trim his front panel a bit though.
You gonna run it on the f20 or f28?

[Adam]

Top work Benn!
A nice Let will finish your car perfectly :cool:

Good price too.

Will look forward to clean up pics, and fitting!!! :)


You'll struggle hiding the fmic, unless you go for a small diesel one or something.
Or do some mods to the crossmember panel

[John]

Some pics or rich's for you benn.
http://i6.photobucket.com/albums/y221/ricmetcalf/DSC00054-2.jpg

http://i6.photobucket.com/albums/y221/ricmetcalf/DSC00029-3.jpg

Can't seem to find any pics of his intercooler though, must have sold it?

[Benn]

Ive seem them, but i dont want the ic on front. I dont want to cut my gsi anywhere that will show.

[Benn]

have a look at rich's for sale threads, iirc he used a frontera intercooler, that fits quite nicely, he did have to trim his front panel a bit though.
You gonna run it on the f20 or f28?

I dont mind cutting the front pannel, and will run the f20.



Top work Benn!
A nice Let will finish your car perfectly :cool:

Good price too.

Will look forward to clean up pics, and fitting!!! :)


You'll struggle hiding the fmic, unless you go for a small diesel one or something.
Or do some mods to the crossmember panel

As said cross member i dont mind, but dont wanna cut my bumper.
Cheers too dude. Will really dive in when the cars at the bodyshop. So i can work in the garage with it and so on. Still just worried it might be a smokie crapper but.

[stevie-p]

just out of intrest whats the best way to polish things?
as i want my rocker cover etc done?

[Benn]

Strip the paint off, then start sanding, 180, 320, 600, 800 1000, 1200. then get some polishing paste on there and workit in.

[stevie-p]

ok buddy thanks a lot

[~~joycey~~]

Just heard the news from dan mate! Looks like a bargin to me :)

[krobinson]

Good work Benn, you rock!

[Lee H]

Coscast head too! If you look at my project thread I have a frontera intercooler but had to cut bumper a bit and the front panel. It's not that noticable though!

[Benn]

Link me Lee? and is it a Cocast?

[Adam]

I know Andy Bishop and Keith Robinson have standard gsi fronts with their intercoolers, but there's were custom made jobbies iirc, designed to fit.

[Benn]

Just heard the news from dan mate! Looks like a bargin to me :)

Cheers dude, Cheers to keith too.. giving me loads to think about..

[Benn]

I know Andy Bishop and Keith Robinson have standard gsi fronts with their intercoolers, but there's were custom made jobbies iirc, designed to fit.

Yeah, but hes just told me the price...:eek: :cry:

[Plug]

yea a let will finish this right off lovely looking shiney nova you have :thumb:

[Benn]

Cheers jim.

[Adam]

Yeah, but hes just told me the price...:eek: :cry:
Yup
GReat setup though, well thought out and fits mint.

[Benn]

Yeah but damn. I dont even have the pot to piss in now..lol

[Lee H]

Link is in my sig benn. Definitely coscast, can tell by the shape of the casting where heat shield bolts on.

[Mike]

Good buy Benn!

Intercooler wise, the twin pass cooler i run, I had next to no modding to the shell at all chap! I did however have to cut both the centre 2 clips off the back of the grille & both the centre lug mounts (where grille mates to bumper) from the back of the bumper.

[Benn]

Cheers Lee, pm on way.

Cheers mike, so you have anypics?

[Mike]

Theres quite a few in my build thread in Member old bean :thumb:

[Jay]

Coooool, whens it going in? :D

[Benn]

Theres quite a few in my build thread in Member old bean :thumb:

Cheers dude,

Jay will be a while yet.

[Jay]

Months, years, decades?

[Benn]

Few months.

[Jay]

Few months.

Cool.

[dan16v]

Pauls told me the actuator rod should be ok.. the two pipes will be replaced while getting hidden.
No f28 ed, space f20 to be sold tho..lol

The lambda will be replaced too.

I want a ic that will fit behind the gsi bumper john, with the less cutted poss...

Benn i have designed a fmic to sit behind the gsi bumper with no cutting, Done this as im looking to have a std bumper with no holes aswell! let me know if you want the details, best bet would be to mock one up out of styra foam or similar! I think it would be around £320 to be made by forge motorsport:thumb:

[dan16v]

ps mate, only just got up off nights and sorry dont have the number you were after! ****

[Benn]

Dude make me one for under a ton...
and thats cool.

[dan16v]

lol no chance! use a rad instead?!lol

[Benn]

Would that work?lol

[The Simps]

Nice snow coverd back grounds from the M1..
http://i22.photobucket.com/albums/b316/bennh3/Road%20trips/IMG_4690.jpg




Looks like your Dad has problems with a floppy disk like my Dad :D

[The Simps]

I wouldn't worry about a smokey turbo too much mate, when you fit the p2 chips (will you will do within a few months of it being on the road) the turbo will need a recon with minutes! lol

[Sloth]

brill, i cant wait for this....

[craig green]

LET ahoy! Nice one.

[Benn]

Cheers craig.

[Ernie]

just noticed what you were on about on msn earlyer now.Sorry mate and nice price.
Well done.

[Benn]

lol wha?

[scott.parker]

Meh!

N/A FTW lol

Nice one ben.

Scott

[Graeme]

Well done mate can't wait to see the updates

[Benn]

Cheers guys, i've got no clue what i'm gonna do yet so tho..

[Rick Draper]

Think the LET lump will make it one of the most perfect novas.

[Adam]

Think the LET lump will make it one of the most perfect novas.

:thumb:

[John]

Agreed rick!

[Paul]

have to agree with Mr. Draper's comment too, nice one Bennyboy!

[Dar]

I agree a LET will make this car simply perfect :thumb:

[Paul]

I agree a LET will make this car simply perfect :thumb:

:eek: Dar turning to the proper engines are you? ;)

[Dar]

:eek: Dar turning to the proper engines are you? ;)
Definitely for Benns car :cool:
EDIT: Not for my bag o' bolts though

[discoinferno]

another powered by a c20let :D

[Benn]

Think the LET lump will make it one of the most perfect novas.

Thank you very much, the means ahell of a lot.


Agreed rick!

Same as above,


have to agree with Mr. Draper's comment too, nice one Bennyboy!


Again as above,


I agree a LET will make this car simply perfect :thumb:

Again thank you all, that does make doing everything worth while, thank you guys, think i love you.

[Benn]

Been a bit lazy, so cracked on today.
Tidyed up my welding from 2003, its held up fine, but as you can see was like bird crunk.

http://img.photobucket.com/albums/v321/bennh/Car%20updates/Endoffeb6.jpg

Not great but a bit better.(seams and old welds are still a bit dirty so)

http://img.photobucket.com/albums/v321/bennh/Car%20updates/Endoffeb8.jpg

Bit better

http://img.photobucket.com/albums/v321/bennh/Car%20updates/Endoffeb3.jpg

Now before as i couldnt hide the top rad hose fully, i just make it look abit better..
http://img.photobucket.com/albums/v321/bennh/Car%20updates/enginebayrebuild3.jpg

As theres now a sencond water hose (from the turbo) i'm gonna join them both them run it to the headertank all hidden.

So i welded it up (purple stuffs a rust proffing stuff)
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Endoffeb2.jpg

Fiber glassed it,
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Endoffeb.jpg

And filled and smoothed.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Endoffeb4.jpg

Thats it now. All finished on my part, Keith should be in tomoz so i can talk to him about paint.

[John]

Good stuff as always Benn! Where's the top hose going to run now?

[Benn]

It will come out, then under the slam, join with the turbo feed one, then thru and up the inner wing to the scuttle to the header tank.

Cheers.

[The Simps]

Good work Benny boy!

rep coming ur way ;)

EDIT: no rep your way as I need to spread the love more :(

[Benn]

Cheers Si, and thank you almost.

[nova_saloon]

this is the first time ive ever seen this thread for some strange reason and i just went through every page looking at everything that you have done. You have a really nice nova btw. but i respect the amount of patience, deication and passion you seem to put in. Nice one

[AlexW]

Looking good dude. Repped!

You will need a LET to make the thing as fast as the XE with all that filer weight hehe

[Benn]

Thank you very much Nova saloon, hope you enjoyed the read, if you look at my mig thread theres links to if all first being done, painted and smoothed and so on.

Trust me AW all the filler is rubbed out, spent all day sanding it all back. Cause its all hard to get to places.

[Benn]

Oh picked this up too,
http://img.photobucket.com/albums/v321/bennh/Crap/IMG_4748.jpg

[Jay]

Looks good benn :) Will be good to see it all shiney again.

Jay.

[Adam]

Good work Benn, going be even smoooother :cool:

[Graeme]

That little army fella gets about a bit doesn't he?

[AlexW]

lol Will be uber kool when its done ;)

Btw Ad nice post count lol

[Benn]

Cheers Jay,

Cheers Ad i hope so. Keep finding stuff to smooth..

Graeme, lol yeah he gets in everything.

Cheers Aw.

[Paul]

good work Mr. Ben, looks all good in tha hood. So is the LET definitely going in now?

[Benn]

Yep.

If it starts to be a hassle it will come out.

[Paul]

Yep.

If it starts to be a hassle it will come out.

Phase 2 and be happy!

[The Simps]

bit of a foot in the 1st pic too ;)

[Ernie]

Aint this all done yet lol

Looking good keep it up.

[Benn]

Been talking paint to day, looks like its going in on thru/friday.

[The Simps]

ooh thats exiting! will soon be time for some boom tish!

[Benn]

lol i cant wait. I just wanna drive my car again.

[dj_wudgey]

good work dude this is going to make a top nova even beter if you ask me!!

[Benn]

Thank you very much.


Opened my ecu, its got a lil damp which might not be good.

http://img.photobucket.com/albums/v321/bennh/Car%20updates/Ecu3.jpg

[Graeme]

That doesn't look the george, is that a damage component next to where it says c900?

[Benn]

No it looks just like a lil rust, cant get the rest open tho..

[Jay]

Looks good Benn, whens it going to be done then?

Will it be out with the Xe in or the Let....

[Benn]

Its getting picked up on friday to go to the bodyshop, be there a week.
While its away i'll be doing work on the let. Then we go from there..
Not rushing anything like time.

[The Simps]

is that the let ecu benn?

[Benn]

Yes :( get fully open it, the rest doesnt look like its got wet tho.

[Ernie]

maybe it was water cooled lol

[Benn]

lol like water cooler pcs.. It just isnt right.

[wilson_sri]

First time i have had a look at your thread in a good wee while. The smoothing is coming on nice, its going to look brilliant.

About time you got a LET aswell! Took your time lol Its really going to round it off perfectly.

[Benn]

Cheers dude. :)

[Benn]

Cleaned all the bay out, and hooved it all.
Took the old loom out, now the scuttles all empty too and cleaned and hooverd too.

Ready to go to the bodyshop now.

[Benn]

So do i need to move the rad forward then? If i do this means less room.

One empty scuttle/bulk head bit.. For for a clean and hoover out.

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_4761.jpg

Poor dusty car... Exhaust system removed.

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_4763.jpg

Raised the rear up by about 2inch...

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_4765.jpg

Started buy bits tho..

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_4770.jpg

And something shiney.. Cause i love it.

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_4767.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_4769.jpg

[Pistol Pete]

Am liking the dipstick/breather tube. Where did you get that made?

[Benn]

Found it on ebay, £26..

[Pistol Pete]

Nice find!!

[L14MNP]

I gotta echo all of the previous comments Ben, your Nova is one of my top 3 and this will perfect it mate!

Love the Action Man? who's always burried under money/parts etc.

Beats every time I have a wad of cash, fanning it out on the table with a handgun of some description lol

[Benn]

Cheers guys,

He jusat gets in the pics.. Has for ages.
Makes me laugh while taking them, so i allways hope it does you lot. Gun are cool tho.

[Ernie]

you fool get on with building it lol.

[The Simps]

you'll need to move the rad benn like i have on my white one. wait till your engines back in to space it perfectly.

[dj_wudgey]

nice buy matey they will look tidy in the bay mate!!!

[scott.parker]

Am liking the dipstick/breather tube. Where did you get that made?

DITO, think thats a nice touch, as there always rusty or grubby! :thumb:

[Benn]

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MEWAX:IT&item=120383267333

See his shop, i've just orderd a few tasty bits.

[Benn]

you fool get on with building it lol.

I want too but got to wait tillthe cars in the bodyshop as i have no room at the mo..


you'll need to move the rad benn like i have on my white one. wait till your engines back in to space it perfectly.

Ggrrr why does no one say these things before hand.

[The Simps]

Ggrrr why does no one say these things before hand.


DUDE!!! Its in my thread, you even questioned it at the time! I even told you on MSN a few weeks back to move the rad 1st before attempting to fit the IC.

Terrible research lol

[Benn]

No. You said about moving it to the center, thats no prob its moving it forward thats the sh**ter.

[Benn]

Right been trying to sort out an ic and that my rad needs to be moved forward. Wanting to keep my fan on the front so i've got very lil room.

So found a thin but long ic on ebay. Start by making a carbboard template up so i could work out what was what. Looks like the front pannel is gonna have to be cut. but not by tomuch.

Rad move forward and to the center.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/icmaking25.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/icmaking27.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/icmaking2.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/Image051.jpg

Ic, bit high here.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/icmaking23.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/icmaking24.jpg

So if i cut this bit off (as in what was sunk in to the front pannel)
http://img.photobucket.com/albums/v321/bennh/Car%20updates/icmaking28.jpg

Which means it will sit like this.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/icmaking22.jpg

But means i'll have to cut this out.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Image050-1.jpg

But means i get this.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/icmaking26.jpg

So i'll be able to just trim the bumper iron down.

[Benn]

Sorry for the crap pics, my phones got dust in it.

[The Simps]

cant beat a bit of blue peter cardboard fun!

Plans look good! I would mount it as low as you can so you will then have more room on the front of the rad for 2 small fans. Also think about where the bumper cut out is.

If you had it start from the bottom of the bumper iton down it'll be about right. You should then be able to mount a couple of 6" fans. I think mine were 8/9".

Here's how mine sat but bear in mind it was very deep/thick. Its goes just below the bottom of the recess and there is what a 2" gap above which should be about inline with the bumper iron. So you might not hve to even cut the iron.


http://img.photobucket.com/albums/v310/TheSimps/Nova/Nova%20LET%20Build/16-08-073.jpg
http://img.photobucket.com/albums/v310/TheSimps/Nova/Nova%20LET%20Build/P2140043.jpg

[Adam]

Which IC is that Simps?

[Benn]

Yeah, but with out the bumper cut out likes yours is i cant go to low.

With it sitting there i can still just get my fan in behind it which i like.

[The Simps]

mine is the 8.1 ltr EDS ones that are really thick, about twice as thick as Shaun's for example Benn. With a thinner cooler you should be able to get it lower with minimal trimming if you really want to keep the fans frount mounted.

[Benn]

Yeah the thinner the better, whats shauns?
The one i'm looking at is 6.5cm wide.

[The Simps]

6.5cm will be similar to shauns.

[Benn]

Right the bit i wasnt happy about doing..

Mark up whats what.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Frontpannel2.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/Frontpannel.jpg

Get cutting.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Frontpannel4.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/Frontpannel5.jpg

Gave me this.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Frontpannel10.jpg

Then marked the top.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Frontpannel6.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/Frontpannel8.jpg

And again to make it stright from the triangle.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Frontpannel7.jpg

Leaves, this. Nice and clean on the insides bar where it was welded around the tie bar mounts.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Frontpannel9.jpg

Now the tie bars are two skins thick, what do i do any strench here?

Fitted the front bumper to see what room i have.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Frontpannel13.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/Frontpannel14.jpg

As you can see still not alot.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Frontpannel11.jpg

But this should just be enough, might need to shave the back out the mouth a tiny bit tho.

[krobinson]

Good work Benn, no going back now!!

[Dar]

Poor car! :cry:
But fair play Benn, it will be awesome once it's all done :thumb:

[Benn]

Cheers Keith and cheers Dar, its kinda like a smile tho...lol
Hope so.

[Pistol Pete]

Where you have cut looks abit close to where you have marked the holes for the rad reposition. Or have i mis read you pics?

Did the piece you cut out come in one piece? You could turn it and re weld it back in, if you see what i mean??!!

Fair play for cracking on with it.

[Benn]

Yes its close to the holes, will have to trim the rubber mounts down.
Yes it came out in one bit, but thinking a thicker bit for added strench.

[fearless]

Looking good so far ben :thumb:


Similar idea to what Rick ended up doing


http://img.photobucket.com/albums/v516/fearlessmotorsport/cimg0029-1.jpg



Dave

[Benn]

Cheers for the pic Dave, just then kinda thing i'm after.
Thats what i was thinking of, adding a thick bit in for strengh, manly for the tie bars.

Thank you too.

[The Simps]

Good work dude, rep your way!!

[dan16v]

http://img.photobucket.com/albums/v211/dan16v/new198.jpg
http://img.photobucket.com/albums/v211/dan16v/5267c046.jpg
http://img.photobucket.com/albums/v211/dan16v/new202.jpg

[The Simps]

^^ thats exactly what the boy needs to do!

when you hoping to get it welded Benn? Bodyshop going to do it? When's the intercooler arriving?

[Paul]

http://img.photobucket.com/albums/v14/lashednova/DSC00339.jpg

I added plate round the tie bars too, when i did this, the do have a tendancy to try and rip the metal! Its loads of force under braking as well as giving it beans accelerating!

What the others have done looks spot on!

The stregth of the crossmember is in its shape, not the thickness, so its needs to be another angular piece welded in like the other hve done.

What intercooler is planned?

[dan16v]

Benn tbh you really need to get the engine into the car with the turbo and manifold in place!, then sit the rad as far back as poss, then start cutting! as you really want the panel flush with the panels below the lights, this gives the cooler max room.
On a LET with the KKK turbo i would look to run the fan on the rear of the rad if poss, like Keith has done, as it's the fans that stand the cooler off from the rad---- which you dont want.

Let with kkk, and fmic to sit behind gsi bumper with no cut out!

http://img.photobucket.com/albums/v211/dan16v/DSCN1009.jpg

Ideal tbh as when you sit coolers into a recessed cross member, and keep the gsi bumper with no cut out they sit too low, leaving most of the core covered by the bottom of the bumper, If you sit them on top of the cross member, they sit right above the upswept cut out of the bumper!

Really all comes down to the size of FMIC you want to run and position of the fan!

[Rick Draper]

http://img.photobucket.com/albums/v211/dan16v/new198.jpg
http://img.photobucket.com/albums/v211/dan16v/5267c046.jpg
http://img.photobucket.com/albums/v211/dan16v/new202.jpg

WTF is that? My eyes, my eyes they are telling lies!

[Benn]

^^ thats exactly what the boy needs to do!

when you hoping to get it welded Benn? Bodyshop going to do it? When's the intercooler arriving?

Thats very much what i have done in the pics above, yes the bodyshop will be welding the bit back in.



http://img.photobucket.com/albums/v14/lashednova/DSC00339.jpg

The stregth of the crossmember is in its shape, not the thickness, so its needs to be another angular piece welded in like the other hve done.

What intercooler is planned?

Gonna be doing like dan's have done as you can see in the pics of what i've cut out.
My tie bars are all welded around anyway.



Benn tbh you really need to get the engine into the car with the turbo and manifold in place!, then sit the rad as far back as poss, then start cutting! as you really want the panel flush with the panels below the lights, this gives the cooler max room.
On a LET with the KKK turbo i would look to run the fan on the rear of the rad if poss, like Keith has done, as it's the fans that stand the cooler off from the rad---- which you dont want.

Let with kkk, and fmic to sit behind gsi bumper with no cut out!

http://img.photobucket.com/albums/v211/dan16v/DSCN1009.jpg

Ideal tbh as when you sit coolers into a recessed cross member, and keep the gsi bumper with no cut out they sit too low, leaving most of the core covered by the bottom of the bumper, If you sit them on top of the cross member, they sit right above the upswept cut out of the bumper!

Really all comes down to the size of FMIC you want to run and position of the fan!

Yeah it would be alot easier, but the engines out so..lol
What i've done is move the rad to the center and move it forward (more so on the o/s as thats where te turbo is) I then made the template up to the size of the intercoolers i've been looking at, sat that in place to work out where stuff will sit. So making sure it will sit behind the bar and behind the gsi bumper. But meaning room for the rad to sit on the front, yes it will be tight but it should work. If it doesnt then i will move it to the back.

So are you saying that its better not to sit them in the cross member?
At the mo mine should sit right behind the open holes in the mouth.

[Benn]

So i walk to to say hello and check shes ok to my nan when i get home and she says something was deileverd earlyer.

Seams its fragile, as showen.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7135.jpg

I opened it like a kid on crimbo morning.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7136.jpg

Ooooo
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7137.jpg

Shiney...
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7139.jpg

Now the ends are a lil wrong, but this is in hand. Been talking to a welder/fab guy that can ally weld 90o elbows in if needed.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7140.jpg

Main reason i went for this was that its very thin, 6cm thick in fact, so this keeps to room needed down. oh and it was very cheap! Which was the main thing and its shiney.

[meritlover]

lol at the tiny man in the huge intercooler

[The Simps]

get it test fitted dude!!

[Benn]

Right fitting.

Sat on the cut out,
http://img.photobucket.com/albums/v321/bennh/Car%20updates/intercooler3.jpg

Ends from the out side,
http://img.photobucket.com/albums/v321/bennh/Car%20updates/intercooler4.jpg

From the in, should be ok with either an rubber elbow or a welded on elbow.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/intercooler13.jpg

Looking down, you can see its behind the line from the irons.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/intercooler6.jpg

Bit tight on the bumper, will shave a bit from the mouth and a lil more from the front pannel (see pic 3down)
http://img.photobucket.com/albums/v321/bennh/Car%20updates/intercooler7.jpg

Sitting right behind the cut out of the mouth.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/intercooler11.jpg

Need to strighten this line up a bit, then it will fit a lil better.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/intercooler8.jpg

:)

[The Simps]

I love it when a plan comes together!

[The Simps]

if you trim the side flaps you'll easilly get some chopped down 90s in there without needing to weld the end tanks

[dan16v]

Looks like it may work mate! are you going to run an f28? is so, make sure the elbow from the cooler to the tb will clear the f28 box mount!

[John]

Where'd you source the i/c benn?

[Adam]

Looking good Benn

[Benn]

Si: Theres enough room i think they will fit, but will if needed.

Dan: May work? Hope it will. Get on msn. No F20 for the mo.

John: Ebay, pm me for the link, hes got a really good shop.

Ad: Cheers. You want the link too? For yours. lol

[Adam]

Aye ;)


Any pics of the cutout in your crossmember?

[Benn]

Yes go back a page.. theres loads...lol

[dan16v]

http://img.photobucket.com/albums/v321/bennh/Car%20updates/intercooler7.jpg

Dan: May work? Hope it will. Get on msn. No F20 for the mo.

Only reason i say that mate, is looking at the above picture, on myne the rad sits almost in the same place as a std set up, just centralised (iirc with kkk rad also has to come forward a smidge?). Looking at the std rad mount holes on the cross member, and the I/C position as it is, I cant see the thickness of the rad and a fan cowling fitting in with out pushing the I/C forward. And did you say the bumper already needs shaving in the position above?

[craig green]

Great progress Benn. Last time I looked you had posted pics of the journey home with the LET in the boot of a Vectra.
I hope its plain sailing for ya.

[Benn]

http://img.photobucket.com/albums/v321/bennh/Car%20updates/intercooler7.jpg

Dan: May work? Hope it will. Get on msn. No F20 for the mo.

Only reason i say that mate, is looking at the above picture, on myne the rad sits almost in the same place as a std set up, just centralised (iirc with kkk rad also has to come forward a smidge?). Looking at the std rad mount holes on the cross member, and the I/C position as it is, I cant see the thickness of the rad and a fan cowling fitting in with out pushing the I/C forward. And did you say the bumper already needs shaving in the position above?


I was told bring it as far forward as i could, so i did as well as putting it in to the middle. With the fan on the front, with the fan right next to the ic, the rads about 1, 1 and a half farther forward from the std place, which i hopoe will be ok. Yes i'll need to shave the the closest in lip of the bumper a bit.

[Benn]

Great progress Benn. Last time I looked you had posted pics of the journey home with the LET in the boot of a Vectra.
I hope its plain sailing for ya.

Cheers dude Its not been to bad as of yet, just bits i hadnt thought about or didnt know.

[dan16v]

Benn, if i were you mate, get the engine and turbo in place, then mount the rad as far back/ close to the turbo as poss!

[Benn]

Thats what i'm gonna do.

[krobinson]

Keeep errr lit sir!!

[~~joycey~~]

Fair play for takeing the plunge and cutting the x-member! Good stuff mate :)

[Benn]

Keeep errr lit sir!!

What?

[Benn]

Fair play for takeing the plunge and cutting the x-member! Good stuff mate :)

Cheers dude.

[Benn]

Started to strip down the let today, first i had to sweep out the inch thin layer of underseal, metal grindings and filler dust.

So got the engine out of its hiding place, and messed about getting in on to the stand, when Astra Dan and Pitstoppedro turned up in a frigging lotus!

Had to take the flywheel off to get the engine bolded on nicely.

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7148.jpg

Pedro loves it.

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7149.jpg

Found that insted of lock tight on the flywheel bolts they'd used rtv...

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7150.jpg

Pass..
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7151.jpg

[Benn]

With the engine on the stand we found that the bottom pully had been off before, with the 4 of the 6 bolts put back in very tight and some pre rounded which was nice. So ended up doing this..

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7152.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7154.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7161.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7159.jpg

Pete left just aftering this... Bye Pete.

So Dan and my self pulled the engine in to the garage to be closer to my tools and carried on stripping it down.

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7164.jpg

I drained the oil out which was like new, which was a good thing.

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7167.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7168.jpg

[Benn]

Cam belt and rollers and water pump are all new, so i'm just putting a new cam belt on, head gasket all so looks new. So wont be taking the head off i think.

Found its got all nice beru leads on it..
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7169.jpg

Plugs out, which look/smell like they've been washed with fuel,

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7170.jpg

Got the inlet off, which has new gaskets too.

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7179.jpg

Down some of the ports.. Clean valves too.

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7174.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7178.jpg

[Benn]

Turbo off.

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7182.jpg

Sooty but clean, no damage on the blades of around the housing.

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7183.jpg

Waiste gate? Move all freely.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7184.jpg

I have two vids up loading of these, the blades/shaft have a bit of movement. But i have no clue if its bad or not.

Oh yeah and the lambda sensor had been cross threaded some how but some funking numtpy. Hole needs a clean up and tap.

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7187.jpg

Left it like this,

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7190.jpg

So i can degrease and clean the block and bits tomoz, then sump off while i paint the block.

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7190.jpg

Big thanks to Dan and Pete for the help today.


Video of the movement on the turbine shaft, it moves but doesnt touch the sides..
http://img.photobucket.com/albums/v321/bennh/Car%20updates/th_MVI_7189.jpg (http://smg.photobucket.com/albums/v321/bennh/Car%20updates/?action=view&current=MVI_7189.flv)

It ok?

[Damo]

Awesome build benn just read it from start to finish awesome attention to detail well impressed. Hope all goes well with the engine when you get it in.:thumb:

Damen.

[Benn]

Thank you very much, hope you enjoyed the read.

[Dar]

That engine looks great! :thumb:

[Benn]

Cheers Dar. Most of it looks good.

[AlexW]

From what i remember from my mates turbo (not a vaux one tho) that its ment to move a little (more backwards/forwards than left/right) That vid it dont look too lose, only way to see is if it chucks out any smoke on booooost! lol

Oh and how rude of me, looking good dude as always.

[Benn]

A few people has said its ok, so i'm happy.

[~~joycey~~]

Turbo looks fine chap, if it was moveing to much that badly it would of already destroyed itself lol

[krobinson]

Turbo should be fine, I got mine Recon'd because the blades wrecked.

Take off the inlet side and check the blades there too.

[dj_wudgey]

good work with the engine bud how long you hoping untill its in?

[Benn]

Turbo should be fine, I got mine Recon'd because the blades wrecked.

Take off the inlet side and check the blades there too.

Cheers dude and will do, will be over to be cut and welded anyway.


good work with the engine bud how long you hoping untill its in?

We cars at the bodyshop now, and i'm striping and rebuilding the let at the mo, would like it in and running by the end of the month.

[Benn]

So deep breath.. Started today off with a bit more striping off...

Had to make spacers when the engine was bolted to the stand, these came in handy..
http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown11.jpg

Like this alot of bolts and nuts on this engine theyve been done up so tight theyve just started to round, which means getting them off is a nightmare.. Like the bolts that hold on the themostate housing (that nicely looks new)

http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown12.jpg

Or like this the jubliee clips unscrew insted of letting go..

http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown13.jpg

Or are Ford ones... lol

http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown15.jpg

So carring on striping, breather/dip stick tube off, new gasket.

http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown17.jpg

[Benn]

Cleaned up the inlet and exhaust mating surfaces.

http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown14.jpg

Dirty.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Day2stripdown-1.jpg

Next thing was a good clean, couldnt find a good simple degreaser. But found this stuff

http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown2.jpg

Mmmmmm Foam.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Day2stripdown3-1.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/Day2stripdown5-1.jpg

Works just like foaming a car, you can see it lift and drag the dirty and oil off as it runs off,
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Day2stripdown4-1.jpg

Best to do out side..lol
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Day2stripdown3-2.jpg

[Benn]

Stray it on and let it work the cans says...
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Day2stripdown-2.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/Day2stripdown2-2.jpg

Oh hello Mr Gm,
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Day2stripdown6-1.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/Day2stripdown7-1.jpg

Model it baby... Model it.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown.jpg

[Benn]

Then comes a really odd bit, washing it off. Felt very wrong washing a block with the hose...
But it comes out very nice and clean after, that stuff is really good and well worth it!

http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown7.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown5.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown4.jpg

With it clean it aloud me to see this,
http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown9.jpg

Being that low does it mean its an early one?

Has 91 cam caps tho..
http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown26.jpg

So with a clean block it was time to paint(even if these are hidden)
Normaly i go black and silver but i thought "ah why not"

Ardon blue core plugs..
http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown20.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown21.jpg

Then a touch of smooth black,
http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown27.jpg

Looks cool in my books..

http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown29.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown30.jpg

Even the back..
http://img.photobucket.com/albums/v321/bennh/Car%20updates/day2stripdown31.jpg

Left it there today.

[Saloony]

And in the background you will see the wheel chair that the turbo lump is being grafted too lol

[R1CH]

Small amount of side to side is ok, its in / out play that you don't want. If theres a bit of in / out play then its probly on its last legs !!
Does it spin freely ?
Take the compressor housing off, if thers any signs of rubbing on the housing (and it has in / out play) then it's probly due a rebuild.

[Jay]

Looks good Ben, will be purchasing some of that degreaser :)

[Benn]

Rich, Yes it spins freely and no it isnt move in and out.
Ment to have been rebuilt all ready, the blue kkk plates been re-riveted on,
the seals look quite new, only having a instand looking gasket on the outer edge.


Looks good Ben, will be purchasing some of that degreaser :)

At £4.80 its worth it.

[Adam]

Good work.
Its so much better working on a clean engine!!!
Saves you getting covered in oil and grease as soon as you lay a hand on it lol

[Benn]

Yeah its much nicer. Need to degrease and wash the garage floor tho..lol

[dan16v]

Looks good Benn! you going to degrease the head aswell? also you not going to remove the head/ new gasket, belt kit, water pump and oil pump for peace of mind?

[Benn]

Head has been, i'll paint it as its well grown in dirt.
The cam belt and rollers and water pump are all new, i'm fitting a new belt tho. head gasket looks new too, as is the rocker cover..lol

Am thinking of taking the oil pump off, checking it and changing the gasket behind it.

[Paul]

That turbo looks fine from what I can see from that video Ben.

Come on, get it in, I was enjoying reading that!

[Benn]

Be a while before its in.

[Dar]

Must have been a day for painting core plugs lol I also did mine, but in normal silver. That degreaser looks like very good stuff.

[Ernie]

Must have been a day for painting core plugs lol I also did mine, but in normal silver. That degreaser looks like very good stuff.

Far to much time .com lol

[Benn]

Must have been a day for painting core plugs lol I also did mine, but in normal silver. That degreaser looks like very good stuff.

Rattle can, 10 coats, 10mins while i had a sarnie.

[Dar]

Crikey. I just rolled up a piece of paper to the size of the core plug and sprayed down that...once. I didn't want to get overspray on the rest of the block.

[Benn]

Paint the block after... I did. lol

[Benn]

So we did a compression test to night, big thanks to Dan!
These where our readings. (engine has no oil, water, cambelt refitted for test, you'll see its a bit lose, no inlet or exhaust oh anything on it)

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7340.jpg

Look right? Wrong? Whys four a bit higher? Engines been sat for a while.

Click the link for the video.... lol * Warning on light swearing, my jeans needing to be pulled up and me sounding like Austin Powers*
We where expecting alot more of a kick when it turned over, hence the bracing our selfs.

http://img.photobucket.com/albums/v321/bennh/Car%20updates/th_Comptest_0003.jpg (http://smg.photobucket.com/albums/v321/bennh/Car%20updates/?action=view&current=Comptest_0003.flv)

http://img.photobucket.com/albums/v321/bennh/Car%20updates/th_Comptest_0001.jpg (http://smg.photobucket.com/albums/v321/bennh/Car%20updates/?action=view&current=Comptest_0001.flv)

http://img.photobucket.com/albums/v321/bennh/Car%20updates/th_Comptest_0002.jpg (http://smg.photobucket.com/albums/v321/bennh/Car%20updates/?action=view&current=Comptest_0002.flv)

[Paul]

1,2,3 are nice and consistent, 4 looks high, especially against 3, as thats 4 bar near 60psi difference...

[Ernie]

you fools lol

[Benn]

Thats my worry Paul,

lol cheers chris.. Thought it would kick alot more tbh.

[The Simps]

you pikey benn! lol

don't LETs suffer on 3 & 4? something to do with the bad design on manifold that it gets hot or something? could be way off!! lol

[Benn]

No idea, thatsd why i've asked for...

[Sloth]

4 is a little high, how longs the lump been sat?

[Benn]

i've had it a while, plus weel or 3 for before i got it. Peeps on Mig have give me enough answers so i'm happy to ffit it and go from there.

[The Simps]

I think the miggers are right Benn.

Just do your sump gasket change, belts etc and put it in. Worst case scenario is head has to come off which is probably easier to do in car tbh as you'll have decent leverage.

[dan16v]

Simps, i take it you have never removed the head from a let fitted into a nova before?lol
I found it alot easyier when i done it the first time around with the engine on a stand lol

[The Simps]

Oh - if you have a stand yes! But not rolling around/propped up against the wall in your garage! lol

The only bit thats tricky while in the car is the belt area.

[~~joycey~~]

Looking good mate :)

[Benn]

Oh - if you have a stand yes! But not rolling around/propped up against the wall in your garage! lol

The only bit thats tricky while in the car is the belt area.

I have a stand, it was taken off so i could do the compression test, now back onit.

Gonna do the sump gasket at the weekend.

Cheers Joycey.

[craig green]

Belt looks slack below the water pump in the vids... Not that it matters I guess?

[Lee H]

Number 4 looks like it has an xe piston in from that reading! All my xe's have been around 14 bar, let's around 11 bar!

Can't think of any possible reason for the high compression!

[Benn]

Belt looks slack below the water pump in the vids... Not that it matters I guess?

Yeah it was a bit slack, we quickly re fitted it to do the test.



Number 4 looks like it has an xe piston in from that reading! All my xe's have been around 14 bar, let's around 11 bar!

Can't think of any possible reason for the high compression!

Can you tell from the under side? as i'll have the sump off at the weekend so i can check then..

[Lee H]

Don't think so. It's unlikely someone would do that anyway but its definitely a strange reading!

[Benn]

Ah ok, and yeah. I will test it again once its in the car and can be run to warm up.

[craig green]

Number 4 looks like it has an xe piston in from that reading! All my xe's have been around 14 bar, let's around 11 bar!

Can't think of any possible reason for the high compression!

Lets hope not!

[Benn]

Think if i could borrow a bore scope, to have a look.

[Benn]

Got on today, got the engine bay on the stand, striped off the timing gear and water pump,
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7342.jpg

Spun it unside down so i could get the sump off,
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7341.jpg

Now i've done this for peiece of mine and to make it look pretty, as the sump wasnt leaking. It had a new aftermarket gasket on it and was very clear so i knew like the rest the gasket was changed.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7343.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7344.jpg

Sump of it was quite clean in there.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7345.jpg

Looks ok.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7346.jpg

Piuckup pipes was clean.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7347.jpg

Everything in the bottom end looks ok.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7348.jpg

All 4pistons look the same from the top and bottom, with the same writing on the bottom. Which should be good.

[Benn]

So i sat down and gave the sump some love.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7364.jpg

Quite damaged and sh*tty.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7366.jpg

First sand down with 180 grit, removed the lettering too.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7367.jpg

The after a 600 git,
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7368.jpg

It then have a quick 800,
The a quick buff on the stiff wheel to see what it came up like. Will be sanded more and buffed on both hard and soft wheels.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7371.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7369.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7370.jpg

Then started on the top, got the rocker cover off, all looks clean again. Pistons look ok from the top.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7356.jpg

Cams look good, no wear.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7358.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7357.jpg

Then took off the cam cap that has the dizzy bit on, as these normaly get forgotten, so i wanted to polish it up nice too.
First prob i has was one bolt wouldnt come off, at first i thought it was undoing the stub too, then found it was just knacked and it was.
Cross thread anyone? :eek
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7362.jpg

Got to just my nut spiltter tho.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7360.jpg

Off ready to sand.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7363.jpg

Thats it till tomoz.

[Ernie]

You tart lol

When do you want to do the sump on mine lol.

[Benn]

Take it off and i'll do it. And gonna be shiney.

[Ernie]

I would but that would mean my car would have to be off the road nooooooooooooooooooooooooooo.
Maybe after the show season has finished for this year lol

ps thanks for the offer also still ok to come down for the wheels some when..


Youve got me thinking now polished gte teardrops hummm.

[Benn]

Nah you dont wanna start polishing stuff.

[wilson_sri]

Sump looks great!

[Benn]

Cheers dude.

[scott.parker]

Nah you dont wanna start polishing stuff.

Sod that, I'm too lazy to keep thing's shiny and polished! i prefer painted (or under sealed at the mo) lol

[Benn]

Sod that, I'm too lazy to keep thing's shiny and polished! i prefer painted (or under sealed at the mo) lol

It is easier.

[Benn]

Right gave Keith a hand pushing the car over there today and droped the iner cooler off so he could sort the cut out.

So my cut out.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Image058.jpg

With the ic in place, the top bit was strighten and the bottom was cut lower by another inch.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Image060.jpg

Some nice thick metal getting welded in.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Image063.jpg

Looking better.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Image061.jpg

14ish gauge (almost 2mm thick) plate welded in, as i wasworried about the strench for the tie bars.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Image065-1.jpg

All done.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Image064.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/Image068.jpg

The bottom of the splash sheld was plated in 03, and coverd in seam sealer, then i've painted it over in blue, when i wire wheeled it all off the sealer had held the water in and it had rusted out.
So it was cut out and plated. And my welds tidyed up.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Image038.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/Image062.jpg

All the weldings done now.

The all of the arch was resealed with a 3m rubberized 2pac sealer, which is the best stuff as it stays rubbery so wont chip. This will then be painted over. (the red light is the inferred heat lamp needed as its 2pac)
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Image066.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/Image067.jpg

Other side will be done tomoz, How it was left today.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/Image069.jpg

Sorry the pics are sh*te, my phones got dust in it.

[Ernie]

nice work mate keep it up.

[Benn]

Will do.

[Count Vaux Alot]

looking good!

[jayme taylor]

tidy job of fitting the ic

[Benn]

Cheers guys.

[The Simps]

good work my southern lover

[Benn]

lol Thank you.

[Jay]

Benn i forgot to say Corsa C brake reservoir caps come without the sensor built in. I know you was asking a while ago.

[Benn]

Ah cool cheers Jay, Aw did offer me one which i forgot to buy..lol

[John]

looking good benn! Lol at the dust in your phone! How's the engine coming along?

[Benn]

Yeah its full of it. Gonna be finishing the sump to moz, need to strip and sand the dizzy housing, and stat housing too. Then buff everything up.

Then the sump can all go back on. Wanna spray the head to clean it up too.
The rocker cover back on, then i can rebuild the inlet.

[John]

We need "buffed " piccies Lol!

[Benn]

Pics of a quick go on the sump 3pages back John.

[scott.parker]

All looking good Ben, that sealer/stone chip's the business mate, thats the sort of stuff i was after, as i wanted to replace and i took off, but don't think you buy it like that?

Scott

[Benn]

Cheers Scott, yeah its the best sealer going.
You can buy, but you'll need an air line as it has a gun attchment.

I can get you the part numberr if you want it.

[scott.parker]

Cheers dude, but I'm not bothering now, already started splashing the underseal all over it! lol

Think there is this shaltz *SP like it on ebay, but you need to buy gun's that attach to the can etc.

Scott

[Jay]

Also Mk5 Astras Benn

[Benn]

Might be scott, but the 3m stuff is really the best stuff.

Cheers Jay, will have a look at the weekend. Altho thinking about it.
The cap from the mk4 isnt the same iirc.

[trackdaynova]

suffed bump! trust you ben!

[Benn]

lol You love it.

[Benn]

Wanted to strip and clean everything. So i started at the top..

Take one dirty inlet manifold, top hat,tb and such.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7391.jpg

Clean ish.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7394.jpg

Top hat off, whats this? (bit with the plug)
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7392.jpg

Should it have two pipes? Guessing it should..
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7408.jpg

Tb off and cleaned, was quite clean on the inside too :)
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7398.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7397.jpg

Breather bit, was totaly clogged up and hard so its been soking.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7396.jpg

Found it comes up well tho.. ;)
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7399.jpg

What do these 3 pipes go tho? Left(bottom) ones the rocker cover small breather isnt it? Whats the other (right) Left top?
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7390.jpg

My dip/cleaning tanks..lol
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7406.jpg

[Benn]

So dirty.. Cant have that.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7401.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7402.jpg

Oh..
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7403.jpg

To strip the innards out you have to knock this roll pin out.. What i mean it beat the sh*t out of it as its very very very tight and well in.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7404.jpg

Christ.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7405.jpg

[Benn]

Been polishing as you know.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7383.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7385.jpg

Couldnt get the sump as nice as i wanted tho, light scratches and edges i couldnt get in too. So i poped to see the boys at Hi-pole metal finishers. Gave them a few bits, but picked this up today.. :) Very happy.
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7410.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7409.jpg

Can see ya face in it he said..lol
http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7414.jpg

http://img.photobucket.com/albums/v321/bennh/Car%20updates/IMG_7415.jpg

Road trip tomoz...

[Graeme]

Looking good Benn, Where you off tomorrow?

[Benn]

You'll see, oop north tho.

[Graeme]

You taking your bucket and spade?