Mid Engine Nova Project

[DaveyLC]

Started with a MINT 1.2 LUXE:

http://www.dohc.co.uk/temp/nova/30-04-08/30042008310.jpg

and this is where it stands:

http://www.dohc.co.uk/temp/nova/27-05-08/27052008380.jpg

I need to seam weld the original chassis rails to what remins of the floor and plate up some bits that I have removed because they were corregated. Then I can weld in the engine rails and think about fitting the Corsa C sub frame.

Obviously the original rear beam is comming out at some point.. at the moment it makes the car easy to move around having it there :D

[vaughanmc]

Will be a mint project if it works out

All the best with it mate :)

[adam c]

looks like a little minter.what engine are you going to be using?

[Steve]

Corsa C sub frame? I like the idea of a mid engined/ rear drive nova but not sure about using a corsa engine.

[DaveyLC]

Plan is to use a Y22XE from a Mk4 astra, the engine has great power and torque curve.. Dont really fancy going down the turbo route as it will no doubt make the car undrivable and I personally HATE the C20XE..

The reason for using the Corsa C sub frame is:

a) The track isn't stupidly wide.
b) The wish bones are mounted to pivot off-center helping to over-come bump steer.
c) Also the track rods are mounted very low on the hubs which helps counter-act bump steer.

Oh and it already has the rear gearbox mount for an F23 Box :)

[Mike B GTE]

sounds like an intersesting project, will be keeping an eye on this one!

could you not have used a slightly less mint shell? seing as you'll be tearing most of it apart anyway it seems a bit of a waste of a minter.

will be very unusual considering your choice of engine.

[DaveyLC]

Dont want to waste my time doing it to a rot box :D I agree though it is a bit of a waste but the car was so cheap I couldnt really say no :D

[vaughanmc]

As they say, better building to a mint shell than a rotten one :)

[~~joycey~~]

looks like its on the p!ss to me? lol

[DaveyLC]

Thats because it is ;) its only resting in the car at the moment until I've finished seam welding the factory rails.

[fearless]

Are you planning on keeping those chassis legs as they are - An engine and box won't fit between them - Trust me - I Know :thumb:


Dave

[DW-Nova]

Looks very interesting. hope it all goes to plan, best of luck and lookforward to seeing some more pics as it progresses.

[DaveyLC]

Are you planning on keeping those chassis legs as they are - An engine and box won't fit between them - Trust me - I Know :thumb:


Dave

The legs are further appart than a standard corsa C bay-legs, the only problem I forsee is that I might have to do some chopping on the passenger side to make some space for the box :)

[DW-Nova]

i can see this thread being a replication of the 4x4 cosworth powered nova, at the start everyone was just moaning and saying nah it wont work etc until they were proved wrong, good luck mate.

[mikey14sr]

Personally I'd rather build a spaceframe unit holding a hayabusa engine with drivetrain and suspension atatched that would simply bolt in, but good luck with it chum.

[meritlover]

from the angle it looks like those chassis sections will be in the way of the struts and driveshafts (this is why front chassis rails are the shape they are, the engine doesnt look like it will go between them, so does the subframe sit on top? making it too high? i havent seen the corsa C subframe, which is why iam not immediatly jumping on the "what a waste of a mint shell" bandwagon, but i shall be keeping an eye on you and your project.

[DaveyLC]

The sub frame goes under neath.. The rails are at the same height as the rails on a corsa c.. and they are the same width.. The track is wider on a corsa C so the turrets will be right next to the wings.

[meritlover]

iam glad you have considered the possiblilities before violating a clean nova. i look forward to a series of pictures also.

it is also better to use a clean nova our RE RWD nova was difficult as there was nothing left 'solid' that the subframe could be welded to and subsequently cracked and failed, due to other projects and customers orders we had to abandon it as there was no time and no more good shells in our yard.

[DaveyLC]

Had some 'issues' with storage but the project is back on course..

http://www.dohc.co.uk/temp/nova/15-06-08/15062008460.jpg

Middle of the factory rails will be chopped out between the uprights for the subframe.

[meritlover]

do you realise how HIGH that things sitting? to keep the car level ,the suspension turrets will have to be low as hell with rediculous angle on the drivesharft, itl eat CVs. i mean, the sub-frame is level with the door locks on the B posts!
or is it just the perception from the photo?

[DaveyLC]

LMAO! You honestly think the sub-frame is going there?? Thats just where I keep it so I dont trip over the bloody thing when im not working on the car.

[djshaggeh]

Im sure Ive seen this car!

Is it stored on a lockup near twyford, near reading?

[DaveyLC]

Yeah it was :) I've had to move it now though..

[djshaggeh]

Haha! I thought so! I was up there on Friday. I noticed it right outside the lockup I go into. Do you or one of your mates own that white mk4 astra van? It looks good!

I nearly took some pics of your nova and posted them on here taking the piss, Im so glad I never!!!!!

Good luck with the project, should be ace when its done!

[The Simps]

sounds like you've thought things out to me mate. Look forward to watching it blossom.

nice to see people trying something a little different imo.

[meritlover]

LMAO! You honestly think the sub-frame is going there?? Thats just where I keep it so I dont trip over the bloody thing when im not working on the car.

.......well, you took the picture? what do you want us to imagine?:roll:

[DaveyLC]

Well it is a SUB-frame, kind of goes without saying that it goes on the BOTTOM of the car lol!


Haha! I thought so! I was up there on Friday. I noticed it right outside the lockup I go into. Do you or one of your mates own that white mk4 astra van? It looks good!


Ah, I know where you mean now ;) just clicked when I saw your sig (taps nose)... It used to be at a unit round the corner thought you might have meant there..

[meritlover]

erm, SUB frame referes to the fact that its a SUB-Assembly that holds the engine and box outwith the chassis.

[DaveyLC]

Jeebus your more pedantic than me lol!

[djshaggeh]

I nearly cried when I saw that you'd cut out the rear arches.

But it all makes sense now!

It was parked next to an uno turbo - which was looking a little sorry for its self! Im sure you know the one I mean. There was also that white mk4 astra van and a dark blue mk3 astra gsi. I dont know how I remember all this, I was in abit of a state.

You'll have to look out for me, I'm up there every friday. Not in the nova though, thats coming up in a few weeks. Usually in a new fiesta, veccy sri or a civic. I guess you have some involvement with the 24hr recovery dudes?

[DaveyLC]

Most of the cars there are scrappers, the recovery place you are talking about is not really recovery he just buys/collects cars and weighs them in :)

You're welcome to come say hello if I'm working on the nova.

[djshaggeh]

Ill look out for you

[novaowner999]

good luck your gunna need it for this thread

[meritlover]

Jeebus your more pedantic than me lol!

it was you that was trying to be a clever-d1ck:p

[DaveyLC]

I don't need to try, it comes naturally.. The clever part that is ;)

[meritlover]

:roll:
we'll seelol lol

[Rexy]

so, the engine your using is the 2.2 from the astra SRi etc? If thats the case then those engines can be made into serious power plants, check out the american sites :D

[DaveyLC]

Yep long stroke 2.2 ecotec.. Nice and torquey with a very smooth power/torque curve :) Not really enough clearence for Z20LET and theres some serious cooling issues and XE's suck IMHO.

[DW-Nova]

Do you have the 2.2 engine yet? if not make sure you look out for the type that dosnt have timing chain problems, i dont know how to find this out, i think it was after a certain date of manafacture or something, at work we have had in quite a few 2.2's and several of them have been nackered, one had a cracked head and blown head gasket and the other had a snapped timing chain so imo theyre not the best of engines. good luck anyhow and look forward to seeing some more pics.

[DaveyLC]

I have been toying with using the earlier Y22SE but the later engine does have much better specs.. I know there are problems with the chains but I'm not sure how common it is.. A mate of mine works for vauxhall and can 'borrow' the chain linker tool the use; with which he recons its not a big job to change the chain to the later spec.

Things are getting serious now:
http://www.dohc.co.uk/temp/nova/22-05-08/22062008479.jpg

[Sturge]

Looks crap, don't think you know what you're doing. And you're not clever, you're a C*nt!








P.S Hi Davey me little snuggle bumpkin lol. Might at least have offered me the shell ya git. Good to see you on a decent site for a change. Now organise a bbq when i'm free :D

[DaveyLC]

Evening you Tartan Warrior!

I've got to attach the sub-frame but im scared lol...

Will be doing another BBQ soon mate :D

[DaveyLC]

oh yeah meant to add an update:
http://www.dohc.co.uk/temp/nova/23-06-08/23062008487.jpg

[DaveyLC]

I am so ****ing happy its un-real! All of my calculations have come together and the car has four wheels (albeit the rears aren't really attached properly lol!)
http://www.dohc.co.uk/temp/nova/29-06-08/29062008519.jpg
http://www.dohc.co.uk/temp/nova/29-06-08/29062008524.jpg
http://www.dohc.co.uk/temp/nova/29-06-08/29062008525.jpg
http://www.dohc.co.uk/temp/nova/29-06-08/29062008526.jpg

[burgo]

that subframe looks extemely low

[Martin]

that subframe looks extemely low

ditto

[DaveyLC]

The rear of the sub frame would normally be on the bottom of the corsa monocoque (under the footwell).. Its actually sitting just as low as it would in the Corsa :)

Also its nice to keep the C.O.G low as possible.

[krobinson]

Looks good, but shouldnt the subframe be about the same height as the back panel? It looks like it will sit incredably high, unless its the angle of the photo.

Keith

[DaveyLC]

This is with the rear arms at FULL sag:
http://www.dohc.co.uk/temp/nova/29-06-08/29062008532.jpg

I took the photo from very very low down...

You have to remember the REAR of the subframe is normally under the footwell on the Corsa.

If the subframe was on the back panel the engine would be touching the roof and with the suspension at full compression the tyres would be peaking out over the rear windows.

[DaveyLC]

I should add, with the wish bones level the tyre is starting to go up into the arch..

[peester]

:eek: crickey dave,.. ur gonna be old n grey when this is done...

good confidence tho.

[DaveyLC]

I started in May this year, so thats 2 months ago.. I've only really been working on it for a month as I had some slight 'ISSUES' with storage.

[Mike]

Dude, that subframe IS to low, is could really do with being around 4" higher up.

[DaveyLC]

The front mounts on the subframe are 170mm from the rail.. If it was 4"higher there would be about 2" clearance between the rail on the sub-frame (not even enough clearence for the driveshaft) and for the wheels to be sat with the top part of the tyre touching the wheel arch the suspension would have to be almost FULLY dropped.

Will get some shots of the car on its belly tomorrow :)

[Martin]

http://www.dohc.co.uk/temp/nova/29-06-08/29062008519.jpg

That weld looks to liek its fixed the thign at thast hight..

[DaveyLC]

I'm not sure what you mean?

Basically the rails are at the same height as the rails are in the Corsa when the nova is at a standard ride height, I then mounted the subframe with the same clearance as the Corsa so in theory it should be in the same position it is on the corsa (at standard ride height) when the Nova is at a standard ride-height and the subframe should be 150mm off the ground (well about 130mm) as the tyres are bigger on the Corsa.

[Mike]

Basically the rails are at the same height as the rails are in the Corsa when the nova is at a standard ride height.

Thats all well and good, if a Corsa had the same ride hight as a Nova to start with ;)

[DaveyLC]

Thats all well and good, if a Corsa had the same ride hight as a Nova to start with ;)

You missunderstand.. With the Corsa at standard ride height I measured where the highest point on the chassis rails lies (the point where the upper gearbox mount is) I then measured that distance from the ground in the back of the Nova with the Nova at standard ride height.. This gives me the correct level for the new chassis rails.. Then from there I mounted the subframe so it is the same clearence from the rails as it is on the Corsa, The Corsa may have a different ride height but regardless of which car the Subframe is in it requires the same ground clearance for the suspension geo to work correctly.. I can mount the car as high or as low as I want on the subframe to get the factory ground clearance for the vehicles body *BUT* the subframe needs to sit at a particular height relative to the ground NOT the body.

[Welsh Dan]

How will you be fixing the rear steering?

[DaveyLC]

A pair of rose jointed track rods..

[The Simps]

looks good to me.

from that rear picture you can see how if the arms are level how much higher they would bring the wheels up.

I think its just cos you're not used to seeing anything there like that on a nova but as you say its not much different to where the wheel well would be.

[DaveyLC]

Everyone has got me paranoid lol!

I'm itching to get down there and drop it down but I'm stuck at work!.. If with the subframe sitting 150mm off the ground the wheel isnt about 1-2" from the wheel arch I'll admit I made a mistake :D

[DaveyLC]

I lowered the car down so the rear is at standard nova ride height.. The subframe is 180mm from the groun (On the corsa C its 150mm).. So now I'm stuck, do I raise just so it looks 'nice' or leave it like it is..
http://www.dohc.co.uk/temp/nova/30-06-08/30062008534.jpg
http://www.dohc.co.uk/temp/nova/30-06-08/30062008535.jpg
http://www.dohc.co.uk/temp/nova/30-06-08/30062008536.jpg
http://www.dohc.co.uk/temp/nova/30-06-08/30062008537.jpg
http://www.dohc.co.uk/temp/nova/30-06-08/30062008538.jpg

[Martin]

still need to be abit lower imo

[BRoadGhost]

You want it so the tiny circles in the steel wheels are hidden by the rear arch

[burgo]

is that your guesstimation of final ride height ?? if so thats way to high. however if this is how it sits without the engine i recon with the engine in you will have got it about right....maybe

[Welsh Dan]

Why don't you fit a wheel of the size you want to fit when its done, sit the car at the height you'll want it at then re-measure the height of the subframe?

[Dar]

Why don't you fit a wheel of the size you want to fit when its done, sit the car at the height you'll want it at then re-measure the height of the subframe?

That's a damn good idea. Looks about right to me. My rear diffuser sits about 180mm from the floor.

Hope it all works out for you :thumb:

[DaveyLC]

Had a busy night!

What do you guys think now

http://www.dohc.co.uk/temp/nova/01-07-08/01072008541.jpg
http://www.dohc.co.uk/temp/nova/01-07-08/01072008542.jpg
http://www.dohc.co.uk/temp/nova/01-07-08/01072008543.jpg
http://www.dohc.co.uk/temp/nova/01-07-08/01072008544.jpg

I'm going to have to rethink the engine mounts slightly but she sits sweet now!

[burgo]

davey dont change it cos we've said so. if youve done calculations and have worked it out do it to how youve worked it out. having said that how its sitting now looks much better

[DaveyLC]

I dropped the car onto its belly and it was just all wrong, when you looked under neath the subframe was hanging off the back.. Geometery wise it was perfect but it just doesnt work on the Nova shell.. Now I've got BAGS of clearance.. I can admit when im wrong lol :D

[The Simps]

as said on previous page, what happens when you add the weight of the engine?

[DaveyLC]

as said on previous page, what happens when you add the weight of the engine?

The struts arent attached to anything yet so the question doesnt even have a purpose? I can make it sit 2 foot off the ground WITH the engine in if I did a couple of mushrooms before I fired up the welder if I felt the need lol

[DW-Nova]

Looks brilliant mate! are you going to make a frame to mount the struts ? looking forward to seeing it coming along.

[DaveyLC]

I'm tubbing the rear for the struts :)

[russpazz]

get in well done you got bollax. hope everything goes ok (i no it wont its a nova. keep us updated n keep the luxe badge on

[DaveyLC]

The LUXE badge has gone, I'm waiting on the rolled steel for the tubs so I've been stripping the body, I've also been working on the RSTurbo behind and stripping an Astra GSi and an Omega so no interesting updates I'm afraid :(

http://www.dohc.co.uk/temp/nova/06-07-08/06072008575.jpg

[vaughanmc]

Will be some car if it all works out mate

Keep it as subtle as possible :)

[DaveyLC]

Well shes' now got a bulkhead and work has started on the inner wings:
http://www.dohc.co.uk/temp/nova/11-07-08/11072008617.jpg
http://www.dohc.co.uk/temp/nova/11-07-08/11072008624.jpg

[The Simps]

looking good thus far dude.

[DaveyLC]

Cheers :)

[shy witness]

some good progress now mate.

very good

[meritlover]

looking well, plenty of strength there for your engine powers!
those masks are very good arent they?
and i do like your recarro style wheel chair!

[DaveyLC]

The Recaro office chair is sooo comfortable its unreal! :D

[L14MNP]

Nice ideas mate, good welding and killer chair :D

[DaveyLC]

Cheers!

[Mboasty]

looking good m8 keep up the good work, seeing all that welding making me wanna start a new project, luv welding/fabricating:)

[jimbob-mcgrew]

impressive man, your brave to try something like this, should be beastly rear wheel drive when its done.

welding on shrooms ... lol

[big dee]

cool to see someone making another one of these, heres one from ni with v6 yumminess that you probably seen at pvs.......

when it was a 2.0 8v turbo:

http://uk.youtube.com/watch?v=4E0darMJ1M8

v6 yummyness:
http://uk.youtube.com/watch?v=ohhIICDrcPU

also, if anyone has footage of the quarter mile done in this nova at santa pod im sure the owner would be greatful if i could get it for him as he was chuffed

[shy witness]

i knew there was a nova somewhere over here witrh the engine in the back...although i never seen it in person.

looks like a good job asweell

[big dee]

to be honest it looks rough, but i guess people dont understand performance over style :D

[DaveyLC]

Yeah im not really trying to make it look sexy, I just want the shell to be stiff :D

[burgo]

i knew there was a nova somewhere over here witrh the engine in the back...although i never seen it in person.

looks like a good job asweellyou means chips??

[Paul]

you means chips??

No, he's from Northern Ireland.

[burgo]

ahhh yes, didnt see that bit

[DaveyLC]

Started tubbing today..
http://www.dohc.co.uk/temp/nova/15-07-08/15072008632.jpg
http://www.dohc.co.uk/temp/nova/15-07-08/15072008629.jpg

[FB_evolutions]

Lookin Pukka My Son

[vaughanmc]

Looks tidy mate - What sort of wheels / tyres you running ? :)

[DaveyLC]

I'd like to run MO's :)

[AlexW]

do love this project looks cool.

[chrisnovaturbo]

them tubbed inner arches are done well mate.

[DaveyLC]

Cheers guys :)

Only a couple of tiny bits to do now.. And hopefully I'll have the turrets done tonight.

http://www.dohc.co.uk/temp/nova/17-07-08/16072008635.jpg
http://www.dohc.co.uk/temp/nova/17-07-08/16072008636.jpg
http://www.dohc.co.uk/temp/nova/17-07-08/16072008637.jpg

[vaughanmc]

Really tidy looking mate

It will be interesting to see it with the turrets in :)

You decided on a colour ?

[DaveyLC]

Already got the paint! :D Pure Gloss White and I might copy the chequers on the new VXR Nurburg.

[vaughanmc]

That would be something else :)

Looks really clean and well presented, colour will make it look awsome

Keep up the awsome work mate

[AlexW]

Would look kool with the astra nurb stuff. I saw one yesterday sounded ace.

[Martin]

i want tubbed rear arches lol

need a damned welder 1st..

[Sturge]

i want tubbed rear arches lol

need a damned welder 1st..

I've got a nice mig for sale lol

[Martin]

and ive just bought a house lmao.... so there for the tubs are on hold for liek ever

[DaveyLC]

I'm really happy, got loads done lastnight.. The car will be sat on its own suspension by the weekend.. Ignore the cardboard templates I had to go source some more 2mm steel:

http://www.dohc.co.uk/temp/nova/18-07-08/18072008643.jpg

[vaughanmc]

Nice big turrets there mate :)

Nice attention to detail with this car, lets hope it all works !

[DaveyLC]

Had a very productive evening!
http://www.dohc.co.uk/temp/nova/19-07-08/18072008652.jpg
http://www.dohc.co.uk/temp/nova/19-07-08/18072008654.jpg
http://www.dohc.co.uk/temp/nova/19-07-08/18072008655.jpg
http://www.dohc.co.uk/temp/nova/19-07-08/18072008656.jpg
http://www.dohc.co.uk/temp/nova/19-07-08/18072008657.jpg
http://www.dohc.co.uk/temp/nova/19-07-08/18072008660.jpg
http://www.dohc.co.uk/temp/nova/19-07-08/18072008661.jpg
http://www.dohc.co.uk/temp/nova/19-07-08/18072008663.jpg

[C7LJN]

Nice work there mate its almost making me want to do some work to my project. Keep up the good work :thumb: :thumb:

[burgo]

pretty handy with a welder aint ya

[vaughanmc]

Really clean and tidy work there mate will be an awsome piece of kit once its done :)

[shy witness]

nice skills mate.



its coming along nicely

[Welsh Dan]

Good stuff.

Any tailgate mounted exhaust gen?
http://www.dohc.co.uk/temp/nova/19-07-08/18072008657.jpg

[DaveyLC]

Nah I want either twins in the middle or one in the standard place.


pretty handy with a welder aint ya

I'm not bad myself still very much learning but I have had a awesome welder helping me along the way, I handed the torch to him to do the major structural bits like the subframe legs and the thick plate I put on the sides of the turrets :D

[DaveyLC]

Nice work there mate its almost making me want to do some work to my project. Keep up the good work :thumb: :thumb:

Coming from yourself that is quite an honor :)

Get that fooking 4x4 finished :thumb:

[The Simps]

looking good Davey!

by the looks of it, with the engine in, ride height should work out ok.

[DaveyLC]

Here's how it sits with the coil overs on the rear..
http://www.dohc.co.uk/temp/nova/20-07-08/20072008670.jpg

Shockingly low (for a car with no enigne) but its stiff as a bitch!

[DaveyLC]

Just ordered some pro-tec arches for the rear:
http://www.dohc.co.uk/temp/nova/novawidearchkit.jpg
My matched front coil-overs are on their way from Europe and I'm on the look out for an engine.. Once the arches are fitted I'll paint the car and hopefully have it ready for Trax :D

[Welsh Dan]

Which engine do you have in mind?

[DaveyLC]

I'm torn!

Z20LET, Z22SE, Y22SE or the new 1.8 VVT.

[Welsh Dan]

Looking at the heat issues chip had with his rwd turbo, I'd say Z/Y22SE.

[chrisnovaturbo]

z20let all the way

[C7LJN]

z20let all the way

yes Z20LET

My mate done this with a a 206 rear engined cossie powered. He had a nice bit of work done on the roof it was like a channel cut in it to flow alot of air to the roof mounted intercooler ( still inside the car tho) looked ace will see if i can find some old pics it was a fue years ago so may take a while:wtf:

[GTE999]

some good engineering going on with this project. im really liking it.

craig

[DaveyLC]

Trimmed the arches tonight so I can tub them out from the insides to create some crud-guards and keep some strength:

http://www.dohc.co.uk/temp/nova/31-07-08/31072008702.jpg
http://www.dohc.co.uk/temp/nova/31-07-08/31072008703.jpg
http://www.dohc.co.uk/temp/nova/31-07-08/31072008704.jpg
http://www.dohc.co.uk/temp/nova/31-07-08/31072008705.jpg

[belly257]

looking good mate:thumb:

[stevenf]

WOW!!! how have i not seen this thread earlier. really impressed with what you have done so far. cant wait to see it with an engine in it. keep up the good work :thumb:

[vaughanmc]

Good work mate - You going to be keeping a similar style 'square arch' like the Nova did have ?

[DaveyLC]

Rally X arches as per my post earlier :)
http://www.dohc.co.uk/temp/nova/novawidearchkit.jpg

[vaughanmc]

Ahh nice one mate will be a cracker once its done :)

Any idea on a colour also ?

[DaveyLC]

Pure white :)

[novait]

still looking good. keep up the good work..

[AlanH]

very impressed. some awesome fabrication work there. bet its a scream to drive when its done. good luck

[mikey14sr]

That's exactly how a wide arch conversion should be done mate, trim out and build a new inner that comes out to meet the new outer, if you can form a 90degree bend on the edge you can bond the outer to it aswell, then seal it up good and proper.

Have you worked out what you're doing for a handbrake yet? As for it to pass an MOT you'll need a mechanical type from what I can remember of the mot rules.

[DaveyLC]

That's exactly how a wide arch conversion should be done mate, trim out and build a new inner that comes out to meet the new outer, if you can form a 90degree bend on the edge you can bond the outer to it aswell, then seal it up good and proper.


My exact plan :) I've got some nice thin guage zinc coated steel to use :thumb:




Have you worked out what you're doing for a handbrake yet? As for it to pass an MOT you'll need a mechanical type from what I can remember of the mot rules.

I was going to use a spot caliper but making up a bracket will be messy.. however I discovered that some of the MK4 astra's (2.0Di van for example) have a mechanical caliper with a 90mm center to center on the bracket (same as the standard corsa calipers)..

Theres a scrapper in at the moment but someone has already dibbs the complete rear beam so I'll have to wait :)

[mikey14sr]

I was going to use a spot caliper but making up a bracket will be messy.. however I discovered that some of the MK4 astra's (2.0Di van for example) have a mechanical caliper with a 90mm center to center on the bracket (same as the standard corsa calipers)..

Theres a scrapper in at the moment but someone has already dibbs the complete rear beam so I'll have to wait :)

Hmm, didn't know vaux were doing that method, I know F*** did on rear disc'd sierra's and the like.

[DaveyLC]

I didnt either! lol, I was very supprised :)

[DaveyLC]

http://www.dohc.co.uk/temp/nova/31-07-08/31072008706.jpg

[mikey14sr]

Yeah just spotted them on EPC, Lucas type not Bosch.

[DaveyLC]

The mounting points are the same distance appart.. I wonder if they will fit on the front hubs im using.

[novashed]

golf calipers no good they have a cable fuction, not sure on mounting points though

[DaveyLC]

The mounting points are wrong :(

[DaveyLC]

I've tub'ed out the rears, ready to be trimmed for the arches.. Not the tidiest sheet roll in the world but its not going to be on display so who cares :D

http://www.dohc.co.uk/temp/nova/01-08-08/01082008708.jpg
http://www.dohc.co.uk/temp/nova/01-08-08/01082008709.jpg
http://www.dohc.co.uk/temp/nova/01-08-08/01082008710.jpg
http://www.dohc.co.uk/temp/nova/01-08-08/01082008711.jpg
http://www.dohc.co.uk/temp/nova/01-08-08/01082008712.jpg
http://www.dohc.co.uk/temp/nova/01-08-08/01082008713.jpg
http://www.dohc.co.uk/temp/nova/01-08-08/01082008714.jpg
http://www.dohc.co.uk/temp/nova/01-08-08/01082008715.jpg
http://www.dohc.co.uk/temp/nova/01-08-08/01082008716.jpg
http://www.dohc.co.uk/temp/nova/01-08-08/01082008717.jpg
http://www.dohc.co.uk/temp/nova/01-08-08/01082008718.jpg
http://www.dohc.co.uk/temp/nova/01-08-08/01082008719.jpg

[draper]

:cool:

some great skills there matey

[djshaggeh]

wow, thats looking good.

ill come over and have a look in the next few weeks

[DaveyLC]

You're more than welcome mate :)

[DaveyLC]

Still no sign of my rear quarters :(

Front bouncey bits came though

http://www.dohc.co.uk/temp/nova/front_struts.jpg

[vaughanmc]

Nice and shiney mate :)

You winding them right down ?

[NovaBoi92]

just read through this whole post, car looks really good. never seen a mid engined nova before. when u putting engine in?

[DaveyLC]

Putting the engine in as soon as I find a suitable one lol :D

[Cormac]

excellent project mate, keep up the good work!

[DaveyLC]

My RallyX arches came today.. I'm well happy :D
http://www.dohc.co.uk/temp/nova/08-08-08/08082008733.jpg
http://www.dohc.co.uk/temp/nova/08-08-08/08082008734.jpg

[vaughanmc]

They'l look mean once there fitted mate, it will have some stance :)

Keep up the great work!

[craig green]

Great thread, great project.

Awesome fabrication going on with this one. I'll keep my eyes peeled on this build.

Keep at it & its nice to see the 'haters' have shut up.

[loggyboy]

where are you doing this dave? id love to come have a nose!

[DaveyLC]

In Hurst mate at my workshop :)

[mikey14sr]

Ahhh, the girth has arrived! Do yourslef a favour though and throw that horrid Dell box out of the window, preferably from an upper floor of a tower block!

[DaveyLC]

The rear quarters are screw fitted. I need to take them off, tidy things up then tiger seal and rivet them in place...
http://www.dohc.co.uk/temp/nova/09-08-08/09082008735.jpg
http://www.dohc.co.uk/temp/nova/09-08-08/09082008736.jpg
http://www.dohc.co.uk/temp/nova/09-08-08/09082008737.jpg
http://www.dohc.co.uk/temp/nova/09-08-08/09082008738.jpg
http://www.dohc.co.uk/temp/nova/09-08-08/09082008739.jpg
http://www.dohc.co.uk/temp/nova/09-08-08/09082008740.jpg
http://www.dohc.co.uk/temp/nova/09-08-08/09082008741.jpg
http://www.dohc.co.uk/temp/nova/09-08-08/09082008742.jpg
http://www.dohc.co.uk/temp/nova/09-08-08/09082008743.jpg
http://www.dohc.co.uk/temp/nova/09-08-08/09082008744.jpg
http://www.dohc.co.uk/temp/nova/09-08-08/09082008745.jpg
http://www.dohc.co.uk/temp/nova/09-08-08/09082008746.jpg
http://www.dohc.co.uk/temp/nova/09-08-08/09082008747.jpg

[LiquidPug]

Quite simply - loving it!!!

[Steve]

Looks good with a set of alloys on, are you getting the wide arch fronts as well?

Also, is that a sparco office chair I spy in the background?

[DaveyLC]

I want to leave the fronts standard :D

Its a Cobra office chair lol :D

[C7LJN]

Looking good mate.

Looks like your rear 1/4s are fitting up nice and easy. Wished mine did Who did you get them from? I used magnum motorsport and never will again :wtf:

[DaveyLC]

I used Pro-tec.. They took about 40 mins to trim and fit :)

[shy witness]

i like .......i like ........i like......



looks the part now i have to say

[8v screamer]

looking good mate, them coilovers look like the ones i got from rennsport.
I was wondering is youve trial fitted and engine and trans in there yet or put a load of stuff in the back of around the same weight to see where its actualy gonna sit as id be concerned about it possibly being a tad low with the weight of a 16v up its bum.
Not picking just wondering :)

Lloyd

[DaveyLC]

I'm changing the rear top mounts over to nova items so they will be under the turrets which will lift the rear by nearly an inch, also the rears are not wound up :)

[8v screamer]

ahhh i see there is method to your madness now, im not a huge fan of 16v engines but am very interested to see how this turns out, looks like fun.
I take it youll use a spun ally fuel tank or plastic race style cell in the front end?

Lloyd

[DaveyLC]

Yeah looking to run a 6 gallon + tank up front :)

[DW-Nova]

looks brill mate, realy coming together now, sorry if you've already said but what's the planned colour for the car.

[meritlover]

this is coming on well, im glad you are managing without my help.

best wishes for the futures of your project. hope to see the further pictures soon!!!

[DaveyLC]

looks brill mate, realy coming together now, sorry if you've already said but what's the planned colour for the car.

I was going to go for a full respray in white, which is why I've removed the windscreen but after some thought I've decided to keep it burgundy :D

[rednova]

excellent fabrication there bud just read through this whole thread, the only thing id be tempted to do is add a few pieces of trangulation where the legs sit against the rear panel and interior bulkhead other than that looks spot on - not sure about leaving the narrow track at the front looks wise.

cant wait to see this finished!!

[DaveyLC]

Sorry I should take some better photos, there are some 3mm webs on the legs :)

[rednova]

Sorry I should take some better photos, there are some 3mm webs on the legs :)

good lad :thumb:

[DaveyLC]

I forgot to post these shots.. On sunday I did some more rust proofing and I made up an adjustable strut brace.

http://www.dohc.co.uk/temp/nova/10-08-08/10082008748.jpg
http://www.dohc.co.uk/temp/nova/10-08-08/10082008749.jpg

Hopefully I'll finish of the turrets tonight, I've decided to use standard nova top mounts as they are far more forgiving for camber adjustment than the corsa C ones.

[vaughanmc]

Looks awsome mate - Good to see your cracking on :)

[loggyboy]

Just noticed the nice message on the roof, are you a member of the ticklers fan club?

[DaveyLC]

Just noticed the nice message on the roof, are you a member of the ticklers fan club?

lol My mate left that for me a few days ago..

I finished of the top mounts tonight, I had to mill down the nova lower spacers/cones as the Corsa C shocks are not quite long enough to use the Nova cones, but its sitting how I want it:

Please ignore the sloppy primer, I did the middle of the strut brace so I can hang it up when its dry and do the ends :)

http://www.dohc.co.uk/temp/nova/12-08-08/12082008750.jpg
http://www.dohc.co.uk/temp/nova/12-08-08/12082008751.jpg
http://www.dohc.co.uk/temp/nova/12-08-08/12082008752.jpg
http://www.dohc.co.uk/temp/nova/12-08-08/12082008753.jpg
http://www.dohc.co.uk/temp/nova/12-08-08/12082008754.jpg

[trackdaynova]

first post in this build thread, despite watching every single update... look awesome, may I add :thumb: certainly a credit to you.

i've only just sold some wide rear quarters that you've just acquired :)

please excuse me if it's been asked before in this topic

but looking at the grade metal boxing you've used, will this not have a major detremental effect on the performance, both handling and acceleration of the car in the end?

unless its thinner wall than it looks?

[DaveyLC]

The box section is 16 gauge (1.6mm) The tubbed sections and turrets are a mixture of 16 gauge and 14 gauge (for stiffness) and the rest is 16-19 gauge..

I had the box section fabricated as one piece and I didnt have a problem lifting it... The steel I have added only weighs a few KG's more than what I have removed from the car :)

The up-rights that join the subframe are very thick wall but they need to be :)

[trackdaynova]

Of course, easy to forget the amount of weight you've removed

Certainly a dab hand at the old welding aren't ya :)

Keep up the cracking progress - great to see the pics :thumb:

[DaveyLC]

Certainly a dab hand at the old welding aren't ya :)
:thumb:

I'm not a pro, but I'm coming on leaps and bounds! I've had a local pro to hand during the whole project who I've been able to turn to for help and advice and ofcourse he's done most of the really tricky bits.. For example I cant weld upside down for toffee lol


The subframe and hubs weigh only a little more than the beam and drums.. The new rails are only a little heavier than the original chassis rails and I've removed the very thick inner arches which were the original stiffness of the shell :)

[DaveyLC]

Took a bit of a step back today, took off the wide rear quarters and decided to make some holes for ventilation, at some point I will fibreglass some vents into the rear quarters.
http://www.dohc.co.uk/temp/nova/16-08-08/16082008763.jpg
I also put some base coat on my strut brace, did some final welding on the passenger side rear quarter, on the rear panel and started work on the drivers side rear quarter which currently has a nice big piece missing which was a bit rusty..

[burgo]

lol that pic looks photoshopped, either that or youve stuck a picture on your quarted lol. deffo dont look like theres a hole there tho

[Sturge]

Davey, get me on msn tonight re your problem on another forum, there's an easy solution ;)

[DaveyLC]

lol that pic looks photoshopped, either that or youve stuck a picture on your quarted lol. deffo dont look like theres a hole there tho

lol I can assure you there is a hole there :D

It does look messed up because you can see the tops of the new sills.

[DaveyLC]

Davey, get me on msn tonight re your problem on another forum, there's an easy solution ;)

Damn I didnt know you were on the MicroPenis support forum too? :eek:

[Sturge]

Not that one!
The bizarre and unusual genital infections forum!!!

[DW-Nova]

Really liking this project now mate, it looks like its being done really well, may i ask, regarding the wide rear quarters you say that you brought them off protec? can you buy them as individual parts instead of buying the entire wide arch kit? as i think i want some wide rear arches for mine but dont want the whole of the kit.

[Martin]

:roll:
Not that one!
The bizarre and unusual genital infections forum!!!

id of gone with the MP one lol

[jimbob-mcgrew]

coming along nicely by the looks of it, rear arches look a tidy fit mate :thumb:
not keen on the huge wheels, but whatever takes yer fancy.
might have to come see this when its finished, not far off.

[DaveyLC]

Dont worry the wheels were just for testing purposes they arent mine.. I'm off engine hunting again tomorrow and I'm having some rear discs machined up so I can hopefully run the Astravan rear calipers.


Really liking this project now mate, it looks like its being done really well, may i ask, regarding the wide rear quarters you say that you brought them off protec? can you buy them as individual parts instead of buying the entire wide arch kit? as i think i want some wide rear arches for mine but dont want the whole of the kit.

Yep you can buy any part of the kit, theres a 7-10 day wait :)

[brainsnova]

DaveyLC if i stayed closer id come to shake your hand since this project is ace and the welding and fabrication is out of this world :thumb:

[DaveyLC]

Thanks mate :)

[AlexW]

There was a C at the scrappy yesterday, shame i didnt take any notice of it.

[Steve]

So you decided what engine your fitting yet? Or you just gonna have alook to see whats available?

[DaveyLC]

Got an engine today, got a 1.8 corsa SRI lump (small block) :)

Hopefully with a decent exhaust and inlet and remap it will see 150 horsies or more and its nice and light, we lifted it into the back of the van by hand.

[Andy]

Excellent,they're fast engines them.Should go well in a nova

[DW-Nova]

Corsa 1.8 sri, They respond well to turbo charging!!

[DaveyLC]

http://www.dohc.co.uk/temp/nova/25-08-08/25082008808.jpg

She's in the hole!

[Steve]

All mounted up? hows the ride height looking now?

[meritlover]

this is coming together nicely, be good to see it on its mounts and looking well.
it will be a good engine once you loose that crappy throttle body!! :D

[DaveyLC]

Its only sat on the rear mount, im still toying with how I'm going to mount the rest of it up :)

[DaveyLC]

Took some very sorry looking subframes...
http://www.dohc.co.uk/temp/nova/rustyseatframes/21082008788.jpg

and gave them a new lease of life:

http://www.dohc.co.uk/temp/nova/25-08-08/25082008814.jpg

Made up some adjuster handles too..

[DaveyLC]

Finished seat sub-frames (bar a lick of paint)
http://www.dohc.co.uk/temp/nova/26-08-08/26082008817.jpg

This is how she sits with the engine in
http://www.dohc.co.uk/temp/nova/26-08-08/26082008819.jpg

http://www.dohc.co.uk/temp/nova/26-08-08/26082008821.jpg

[The Simps]

I'd say you've got the ride height about right!

Anypics off the car underneath from the back for ground clearance?

[DaveyLC]

Will get some shots tonight if I remember :)

[AlexW]

Looks kool, Good job. When do you plan to have it finished?

[novait]

looking good fella...keep up the good work..

[meritlover]

it sits very well with the frame taking the weight of the engine. have you considered how to connect up the gear linkage yet?

[DaveyLC]

I'm really happy with the fit and position of the engine. not sure about the linkage yet, I'm going to try and source an MGF shifter and cables and see how I get on with that.

[meritlover]

i was going to suggest cable operated linkage. i wish you well, it is often the small tasks of linkages and clutches that prove to be the most frustrating and mentally demanding.

[DaveyLC]

I'm good with stuff like that.. I get depressed by the menial tasks :(

[DaveyLC]

Started work on the gearbox mount tonight

http://www.dohc.co.uk/temp/nova/28-08-08/28082008824.jpg
http://www.dohc.co.uk/temp/nova/28-08-08/28082008825.jpg
http://www.dohc.co.uk/temp/nova/28-08-08/28082008826.jpg

[Spudly]

Looking good matey i really cant wait to hear/see this beasty in person (hopefully lol)

[DaveyLC]

Pulled a late one, I just got home but I made LOTS of progress :)
My front engine mount (to subframe) master piece which I'm very proud of :D
http://www.dohc.co.uk/temp/nova/30-08-08/30082008833.jpg
http://www.dohc.co.uk/temp/nova/30-08-08/30082008837.jpg
Rear upper mount (I'm going to change this for the torque bar).
http://www.dohc.co.uk/temp/nova/30-08-08/30082008836.jpg
Gear box mount/hanger:
http://www.dohc.co.uk/temp/nova/30-08-08/30082008835.jpg
One solid and straight engine:
http://www.dohc.co.uk/temp/nova/30-08-08/30082008834.jpg
http://www.dohc.co.uk/temp/nova/30-08-08/30082008831.jpg
http://www.dohc.co.uk/temp/nova/30-08-08/30082008829.jpg

[shy witness]

more top work mate.


nice skills with the mountings and that.

very good.

[DaveyLC]

I just realised, I bought the car exactly four calender months ago from today :D

http://www.dohc.co.uk/temp/nova/30-08-08/30082008841.jpg


Oh and the finished mounts, forgive the messyness of the weld I was running at near fullpower and its not quite as easy to get a nice bead..

http://www.dohc.co.uk/temp/nova/30-08-08/30082008842.jpg
http://www.dohc.co.uk/temp/nova/30-08-08/30082008844.jpg

[Rickyb]

i like this project it should be good once done :thumb:

[RSTChris]

Nice project, good skills!

[AlexW]

Great work as per usual. Cant wait to see this finished!

[DaveyLC]

A big thanks to Colin (RallyNova) for bringing down a rollcage!

I've spent most of the day working on the loom and hopefully tomorrow I'll be collecting an MGF gear selector and cables.

[AlexW]

*cough* its novarally *cough*

Whats left on the to-do list now?

[chrisnovaturbo]

be good to see how this engine goes in a nova

[blacknovagsi]

what gearbox you using with the corsa engine? is the block the same as the 1.6? top quality build by the way, im propa jealous:cry:

[DaveyLC]

*cough* its novarally *cough*

Whats left on the to-do list now?

Oops lol

I need to:

Finish the loom.
Chop up then weld in the rear part of the roll cage.
Sort out the gear shift.
Some how fit my rear calipers.
Fit my new front brakes.
Install a land-rover clutch master cylinder.
Source some wheels.
Remove the engine then respray the car.

And various other bits and bobs.


what gearbox you using with the corsa engine? is the block the same as the 1.6? top quality build by the way, im propa jealous:cry:

Its the same as the 1.4 and 1.6.. I'm using a gearbox from a Corsa C no idea what box it is lol :D

[LEWI007]

I hope this isnt going to be another of those projects where the guy just gives up half way through and scraps the car. If you finish this thing off its going to be one sick nova, It's going to be RWD right ? :thumb:

[meritlover]

its going to be mid-wheel drive because its mid-engined ;)

this project is as good as finished. the hard graft is done, and the construction looks sound, the finnishing touches are just the ancillaries. theres been too much work put in to give up now

[Stuart]

its going to be mid-wheel drive because its mid-engined ;)


so when is the 3rd axel of wheels going on then? :P

its RWD but mid engined... although to be pedantic the centre line of the engine is behind the driveshafts to the wheels to "technically" its rear engined RWD lol

[DaveyLC]

although to be pedantic the centre line of the engine is behind the driveshafts to the wheels to "technically" its rear engined RWD lol

Nope, the engine is IN FRONT of the drive shafts..

[loggyboy]

although to be pedantic the centre line of the engine is behind the driveshafts to the wheels to "technically" its rear engined RWD lol

Looks mid to me

http://www.dohc.co.uk/temp/nova/30-08-08/30082008829.jpg

[LEWI007]

rear engined rear wheel drive nova :D should put some of those vents along the rear window :p

[nova_niek]

mmm nice :-)

[hendrix]

maybe a n00bish question but have you thought about using the hole for the fuel filler as an air intake for the engine?

[DaveyLC]

maybe a n00bish question but have you thought about using the hole for the fuel filler as an air intake for the engine?

The hole is covered up :)

[Stuart]

Looks mid to me

http://www.dohc.co.uk/temp/nova/30-08-08/30082008829.jpg

ahhh yeah lol get a non turbo fitment F23 on there :D then it can be behind the wheels :D

[vaughanmc]

Engine looks awsome sitting there

You having an air intake coming via the rear 1/4 window ? :)

[mikey14sr]

All that needs now is a nice alloy cover over the top to keep the fumes out, nice work on the mounts matey.

[DaveyLC]

Picked up an MGF shifter today and modified the standard linkage so it has the right size ball joints, fitted the cables and realised the bloody mgf shifter 'left + right' pivot is the wrong way round.. ****!

[novarally]

I had a tour round this car on Sunday night, and was very impressed. Lots of hard work has gone into this.

Looking forward to keeping up with progress............just 4 months to get this far working on it part-time is great going.

[DaveyLC]

Cheers Colin :D

[tom_beverley]

Seemed to have missed this one, good work :thumb:

[DaveyLC]

The rear mount was a bit 'saggy' with the land-rover mount so I've used the proper torque-bar:
http://www.dohc.co.uk/temp/nova/02-09-08/02092008851.jpg

I've got a hole just in front from the old mount so I'll probably add on a little 90 degree re-inforcement.

Started fitting the cage:
http://www.dohc.co.uk/temp/nova/02-09-08/02092008852.jpg

[just vaux trev]

is this gonna be to show off or sleeper-ish........just thinking van pannels

[DaveyLC]

Never really going to be a sleeper with the big wide rear arches.

[hybridturbo]

Nice progress here, your making it look very easy

I bet its bloody not though :)