Ades Drive V1.0 (1.3 SR touch up)

[ade]

lol

As you know my garage is full to the brim with my other rebuild (See Ades Garage - which needs updating) and not content with moving house and everything else I've got going on at the moment I thought I'd start another project - so welcome to Ades drive!

This project will be pretty straight forward and involves me tidying up my new baby - a 1988 Vauxhall Nova 1.3SR purchased a couple of weeks ago.

The car is pretty much standard - the only mods are a set of Belmont 14" wheels, a slightly different exhaust system and a set of sport style decals on the bonnet and boot.

The objective is to get as much as I can possibly do before the August bank holiday "posing" weekend.

Here's my project list -

Body Work
replace front wings
replace upper slam panel and repair inner arch corners behind lights
replace rear arches and repair inner arches
repair fuel filler area
replace vynal inc b pillar and possible hatch vynal with "new" ( * )
repair rust spot behind rear bumper and reseal rear panel
clean up and chassis black the entire underside
waxoyl all panels
replace mk1 bump strips with new ones (if possible) ( * )
clean up overspray on front bumper
colour code mirror covers
replace windscreen with new spare one
replace rear light units (there's a crack in one)
paint all replacement panels
remove the red strip
remove the sport style stripes

Engine and bay area
clean up engine bay paint work - derust, reseal and respray
clean up engine - degunk and tidy up
clean up fluid tanks
fit weber 32/34 dmtl carb and get engine tuned

Brakes, suspension and steering
replace 1.3 SR brakes with GTE/GSi units including servo/master cylinder ( * )
fit new discs and pads
replace track rod ends ( * )
replace bushes with poly units all round ( * )
replace bearings front and rear (there's hum from the left side when cornering and doing 40mph) ( * )
tidy up hubs and suspension components

Interior
Clean interior thoroughlyfix drivers seat bolster ( * ) - need a bit of material of similar style velour
clean up oil/dirt patches on head lining and door cards
fix dash clocks (speedo's a bit off)
replace gear stick gaiter rubber (it's split) ( * )

General
Give the car a ruddy good wash and polish
Do a full service
refurbish original set of SR wheels and get new rubber.


As always I'll post up pics as I complete each section.

I'm also after parts so check out the wanted section to see if you can help me out - items with a star ( * ) above denote the bits I need...

:thumb:

[g111mds]

saw the pictures on the other thread and looks good. I'm going to be needing a full set of SR vynal for mine as well so will be interesting to see how you get on with it.

Did you get it local?

[ade]

yeah - was in ebay for a while but didnt meet the reserve - guy lives near me so popped round and took it off him. I love it!

I'm tempted to make up my own vynal - just need to find a decent sign makers...

[g111mds]

excellent! I think if you can get the templates made up and someone to produce half decent replicas, there'll be a bit of money to be made here!

[bangerbrian]

a 1998 Vauxhall Nova 1.3SR purchased a couple of weeks ago.

^^ never knew they made 1998 novas lol

[SRimon]

Or 1.2 SR's for that matter ade ;)

[Mike]

lol i see you like me can never stop tatting with Nova's Ade :D

[vaughanmc]

Looked really nice at PV mate :)

Will be good to see what you do with this one

[ade]

lol - erm yeah dislexyc moment there - 1988 1.3 SR...

amended

[NOV4_SPORT]

Nice one mate, look pretty good when we stoped on the way back from pv !
Ps have you got the pics of my sport ?


iain

[DW-Nova]

Whats happening to the other project then mate? this sounds a good little project, sorry if you have said already but whats the idea with the 1.3sr once it's done then? whats the bodywork like in general?

[ade]

other project is still going strong (although the missus is convinced its not going to get done!).

SR's body is solid - just rear arches and wings which will be sorted in the next month or 2.

It's also gonna stay totally standard!

[ade]

Monday 23/06/2008
Parts arrived today and over the weekend -

Track rod ends
Rear bearings
front drivers wing
2 rear 1/4 panels
etch primer
glacier white paint
Still waiting on poly bushes, front wheel bearings, servo and master cylinder and PU7 joint sealer.

Still need a set of GTE/GSi brakes...

[CoolTiger]

seen it at pvs look good base :)

plus empty ur pms :P

[vaughanmc]

Good progress mate - You will have 2 lovely Nova's once there both done :)

[draper]

woohoo - mk1 SRs FTW

r.e the vynal i have an idea ade but your inbox is full ;)

[ade]

Inbox is now empty... I blame xxxNovaxxx - love you too Dave!

[ade]

Thursday 26/06/2008
Day off so I thought I'd start work on the SR.

Started by removing the front bumper. Both wings need replacing but I wanted to test fit a pattern wing I'd bought from Beavers auto parts. Only cost about £20. I'll not be removing the wings until I'm ready to rteplace the top slam panel which is pretty rusty in places.

The bumper is also a little wonky - seems to have been pushed to one side a tad - just the brackets need realigning - however I know at some point the front ends hit something - only lightly though (bonnets got some runs on the underside).

The worst wing-
http://img.photobucket.com/albums/v13/danga/drivewing.jpg

Passenger not soo bad but is dented-
http://img.photobucket.com/albums/v13/danga/passwing.jpg

Lower valance is really solid (which suprised me) but the centre suppert has taken a knocking at some point -
http://img.photobucket.com/albums/v13/danga/dent1.jpg

Just bent it back...

So with drivers wing off (which was pretty easy) I offered up the pattern part and was amazed at how well it fitted!

http://img.photobucket.com/albums/v13/danga/wingpanel3.jpg

The front lines up perfectly!
http://img.photobucket.com/albums/v13/danga/wingpanel2.jpg

There's a little bit of fettling needed on the corner - just the metal lip is too sharp and just needs tapping round and the edge by the wondow needs tapping in -
http://img.photobucket.com/albums/v13/danga/wingpanel1.jpg

But apart from that its brilliant!

So next task was to prep the wings. I'd actually got a set of Colin Smith at PV but the drivers one was fecked after I'd "probed it" (a great big dent that'd been fillered over). So after prepping the other one and then flatting back the pattern one I gave them both a coat of zinc primer/etch primer the other day. Today I gave them a coat of standard white primer -
http://img.photobucket.com/albums/v13/danga/wing2.jpg

http://img.photobucket.com/albums/v13/danga/wing1.jpg

The other day I also prepped up the new slam panel I've got - it just needed flatting back and I sprayed it in zinc primer.

[ade]

Thursday 26/06/2008 - continued...

...the slam panel was primed the other day so I just flatted that back a little and sprayed it with the final coat. There's areas I need to sand back though because it needs welded in place so I'll probably give it one final coat once welded in place.

http://img.photobucket.com/albums/v13/danga/slamsprayed2.jpg

http://img.photobucket.com/albums/v13/danga/slamsprayed1.jpg

http://img.photobucket.com/albums/v13/danga/slampanel2.jpg

http://img.photobucket.com/albums/v13/danga/latch1.jpg

As for the innerwheel arch on the car it's in pretty good shape - the splash back part is pretty rusty so I brushed it back and gave it a lick of Krust for the time being - I'll probably end up cutting this out and welding a new one in its place...
http://img.photobucket.com/albums/v13/danga/wheelsplash1.jpg

the slam panel defo needs replacing - also need to add a bit of metal to the lower part of the inner arch behind the slam panel where the water's drained out and caused the damage...

http://img.photobucket.com/albums/v13/danga/rust1-1.jpg

[Adam]

Nice work Ade.

Using a compressor for the spraying? Or cans?

[ade]

cans - sprayed the slam panel and it came out really well.

The best thing about white paint is its very forgiving - it doesnt show up faults at all.

[DW-Nova]

looks good mate, those wings seem to look pretty well fitting too, hows the other car coming along too?

[ade]

Saturday and Sunday 05 and 06 July 2008

This weekend I are mostly be fitting my new upper slam panel.

The current ones "okay" but the drivers wing is buggered and the corner drain plug on the inner arches is rotten so needs sorting.

Started by removing all ancilliaries -
http://img.photobucket.com/albums/v13/danga/DSCF0011-1.jpg

Heres the main damage -
http://img.photobucket.com/albums/v13/danga/DSCF0012-1.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0015-2.jpg

Found and drilled out all spot welds using a spot weld drill bit

Removed old panel -

http://img.photobucket.com/albums/v13/danga/DSCF0020-1.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0021-1.jpg

Stripped bits off old panel (vin plates, boot clip and mounting clips)

http://img.photobucket.com/albums/v13/danga/DSCF0022-1.jpg

Made a card template and cut all the old rust off the inner wings behind where the panel sits - both sides were in poor shape but the drivers was worst -

http://img.photobucket.com/albums/v13/danga/DSCF0023-1.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0024-3.jpg

checked fit and fettled -
http://img.photobucket.com/albums/v13/danga/DSCF0025-2.jpg

tack welded new part in place -
http://img.photobucket.com/albums/v13/danga/DSCF0026-1.jpg

continued...

[ade]

continued...

welded it up (both sides) and ground back -
http://img.photobucket.com/albums/v13/danga/DSCF0027.jpg

Did the other side to match and then acid etched both panels and other exposed metal -
http://img.photobucket.com/albums/v13/danga/DSCF0029-1.jpg

Test fitted the new panel-
http://img.photobucket.com/albums/v13/danga/DSCF0030.jpg

Realised I shouldnt have bothered spraying the areas to be welded because the pain just caught fire! Anyway - drilled holes to plug weld through, lined up and clamped in place -
http://img.photobucket.com/albums/v13/danga/DSCF0031-1.jpg

Panel welded in place awaiting clean up -
http://img.photobucket.com/albums/v13/danga/DSCF0032-2.jpg

Drivers side welds ground back awaiting more etch primer and sealed before final primer and paint (again!). passengers to do Monday (got too late to grind)...

http://img.photobucket.com/albums/v13/danga/DSCF0033-2.jpg

:cool:

[belly257]

looks top work mate:thumb:

[vaughanmc]

Looking good mate

Will be awsome once its all done :)

[ade]

cheers. This is fairly straight forward - the bit I'm worried about is the rear arches - both sides need doing and the drivers side has to get some soon because the corners missing. The rain we're havong isnt helping matters.

I'm off Thursday to Monday inclusive so "hopefully" weather permitting I'll get it done. Just wish I had a double garage to move around in...

[ade]

Monday evening 07/07/2008
Spent most of this evening grinding back the welds, etch priming and then applying a nice thick payer of sealant all round the new panel edges. Once that's cured I'll prime it, flat it back and then give it a final top coat.

[Adam]

Nice work Ade :)
Will you be doing the arches yourself too?

[vaughanmc]

Good work mate - Cracking progress

Will this turn into your daily drive ?

[ade]

yes it's my "daily drive" although it's been off the orad for a week!

Arches wise - yes I'll be doing them meself - see below...

[ade]

Thursday 10/07/2008

Today I are mostly fixing my rear arches. Decided to start with the worst one - the drivers side. The filler neck is shagged and needs repairing but thats only the start!

Heres some pics of the state of the arch -
http://img.photobucket.com/albums/v13/danga/DSCF0002-1.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0004-4.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0013-1.jpg

Started by stripping the interior out of the car and removing the rear bumper. Discovered whilst doing so theres several rust patched in the boot area. I knew about a couple but discovered a couple more which is a pain in the bum. More excuses to practice my welding!
http://img.photobucket.com/albums/v13/danga/DSCF0009.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0010.jpg

Once that was done I decided to drain the petrol tank. I need to replace the fuel sender and return pipes as theyre all cracked. Undid the jubilee clips and let it pour out. It was supposed to be just above the red line however it kept coming out!
http://img.photobucket.com/albums/v13/danga/DSCF0012-2.jpg

Once that was done I removed the filler neck. Found half a field in soil around it too!
http://img.photobucket.com/albums/v13/danga/DSCF0014-1.jpg

The next task was to find clean metal. I knew from peeking under the arch that the inner one was shot sho needed to cut about 3" back. I also needed to take into account the filler area. Thankfully my new panel has 1/2 a filler on it. I measured out approx cutting area -
http://img.photobucket.com/albums/v13/danga/DSCF0016-1.jpg

new panel
http://img.photobucket.com/albums/v13/danga/DSCF0017-1.jpg

sanded back the paint to ensure good metal beneath -
http://img.photobucket.com/albums/v13/danga/DSCF0018-3.jpg

continued...

[ade]

continued...

removed spot welds -
http://img.photobucket.com/albums/v13/danga/DSCF0019-3.jpg

cut the old panel out including some of the filler neck -
http://img.photobucket.com/albums/v13/danga/DSCF0020-2.jpg

had a bit of a paff with the bottom of the arch - had to cut most of it away -
http://img.photobucket.com/albums/v13/danga/DSCF0021-2.jpg

a bit annoyed as the inner lining around the filler nexk was shagged so need to cut that away and patch up -
http://img.photobucket.com/albums/v13/danga/DSCF0022-2.jpg

The inner arch was pretty poor and in several areas totally missing. I decided to cut away the same amount of material from the inner arch matching the exterior one -
http://img.photobucket.com/albums/v13/danga/DSCF0025-3.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0026-2.jpg

This can now be layed up against the new panel and a replacement made.

Here's a shot of the filler area fron inside -
http://img.photobucket.com/albums/v13/danga/DSCF0027-1.jpg

The rusty bits will get cut away.

Next task was to remove the so called rust proofing all round the arch. this will stop it burning when welding
Back edge
http://img.photobucket.com/albums/v13/danga/DSCF0028-2.jpg

Top
http://img.photobucket.com/albums/v13/danga/DSCF0029-2.jpg

filler area with rusty bits a bit cleaner...
http://img.photobucket.com/albums/v13/danga/DSCF0030-1.jpg

continued...

[ade]

continued...

I then clamped the new outer skin to the body -
http://img.photobucket.com/albums/v13/danga/DSCF0032-3.jpg


The idea is to draw a line from the inside so that the panel can be cut to fit accurately. masking tape was used to show up the line -
http://img.photobucket.com/albums/v13/danga/DSCF0035.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0036.jpg

Before cutting the external skin, I needed to make an internal one.
Here's the old inner arch skin against the new panel. you can see how much is missing -
http://img.photobucket.com/albums/v13/danga/DSCF0038.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0039.jpg

Making a replacement could have been time consuming however I decided to buy another set of external arches and modify these to act as inner ones. Some modification is needed to ensure they fit the outsode skin snuggly) but that's much eacier than trying to make a skin from scratch. So I knew how much material to cut away, I drew around the old inner arch using tape to see the line -
http://img.photobucket.com/albums/v13/danga/DSCF0040.jpg

This was then checked for fit -
http://img.photobucket.com/albums/v13/danga/DSCF0041.jpg

Which was pretty good.

Before tacking in place I needed to sort out the inner filler skin. I made a replacement part -
http://img.photobucket.com/albums/v13/danga/DSCF0042.jpg

And welded it in place (welds only half ground back) -
http://img.photobucket.com/albums/v13/danga/DSCF0044.jpg

I repeated the process for the outside -
http://img.photobucket.com/albums/v13/danga/DSCF0043.jpg

Once the arch is complete they will be cut to fit the round of the hole.

continued...

[ade]

continued...

I then started to weld the inner arch. I started by lining it up. because it's a awkward area to work in I'd purchased some special clamps to secure the panel in place - pics show the back of the clamp bar. once tack welded a fly nut is undone and the bar removed allowing the clamp to be extracted. Clever -
http://img.photobucket.com/albums/v13/danga/DSCF0047-1.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0046.jpg

Welding the inner arch was a real pain in the anus. I started by welding the outside edge 1st and then started to weld the inside just to be 100% sure of full penetration. My welding skills are a bit patchy and getting a steady full penetration weld isnt easy, but I was pleased with what I'd accomplished right up to my fecking gas running out half was along the inside edge! I thought I'd bought an extra bottle too but didn't!

And welding inside is fecking impossible - you cant get a helmet in there so you end up sitting outside and pre guessing the area based on the reg blob that shows on the outside!

Anyway - heres the outside with the welds half ground back.
http://img.photobucket.com/albums/v13/danga/DSCF0050.jpg

I'll finish the rest tomorrow once I get more gas (and wire!)

After I'd tidied up I decided to shutz the front area of the car I'd replaced the other day. I'd applied a couple of coats of chassis black to the light housing area and this had cured so the shutz was sinply applied all over the most rust prone areas including the radiator bottom area and the lower alsm palen. I also welt over the inner spach arches and down the sides beneath the drain plugs from the skuttle panel...

http://img.photobucket.com/albums/v13/danga/DSCF0048-1.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0049.jpg

Should last a few more years!





:thumb:

[Dave.]

looks very snazzy ade.. good skills there too

exactly what i was doing on work experience last week lol :thumb:

ps.. did you find that pic? and are you going to put the model pics on your website? :thumb:

[AlexW]

Nice... This really made me not be quite so scared of repairing my passenger arch! Daily drivers are never daily, they always need somthing doing!

[ade]

Dave - nah - god knows what happened to it! And the modelnoavs site is painfully out of date - another project that needs updating...although I'm considering an overhaul of that too...

[Ste L]

good effort ade - wish i had room to do stuff like this :(

[vaughanmc]

Body Schutz is the game like

Good work Ade :)

[jimbob-mcgrew]

looks challenging that, your doin well, those 4 spokes are ace

[GTE999]

hi mate

good progress. i noticed you had some problems with the splash guards. When i was sorting mine i found the splash guards to be corroded which led to water leading into the interior and causing a few holes. I basicaly had the interior holes welded up along with the splash guard. The reason im saying is because your doing alot of work to the car and if you check under the carpet and the drivers side inner panel youll see corrosion and its probably best to sort this just now. btw its a pain in the backside to sort! good luck.

cheers
craig

[ade]

cheers matey - had checked and the inner walls are fine (unlike my other Nova project - had to get new splash guards made!)

[ade]

Friday 11/07/2008.
Didnt get too much done today due to viewing a new house (which was stunning) but mamaged to get a couple of hours in tonight.

Spend most of the evening adjusting the inner arch to fit the outer one.

Started by cutting the outer skin to the right size. I left a little extra just incase and offered it up for sizing. It's a really good fit -
http://img.photobucket.com/albums/v13/danga/DSCF00011.jpg

http://img.photobucket.com/albums/v13/danga/DSCF00021.jpg

I then had to modify the lower corners. As you know I used another outer skin for the inner skin so to make them fit I needed to cut some material away from one of the edges, push it back a bit and weld it up. now it fits perfectly.

The next task was to run a line around the outer panel to get a perfect fit line-
http://img.photobucket.com/albums/v13/danga/DSCF00031.jpg

I can now grind away the excess metal from the body to get a perfect fit onto the existing panel.

Unfortunately by this time it was 9pm so a tad late to start grinding.

So I decided to finish off one of my front wings. One of them is brand new so has no inner protection except for the black factory primer. I'd applied a coat of chassis black to the whole of the inside earlier in the day and finished by applying a nice thick layer of shutz. the other wing already had a generous amount of shutz applied.
http://img.photobucket.com/albums/v13/danga/DSCF00051.jpg

Got this off ebay (3 for £7) its designed to be sprayed but can be painted easily enough. I actually bought some proper applkicator nozzels to use with my spray gun but couldnt bloody find them!

10 mins later and the wing was fully protected! You cant really see it from the pic though...
http://img.photobucket.com/albums/v13/danga/DSCF00061.jpg

Saturdays game is to get up early (he says!), finish the engine bay/wing area and then start the rear arch. If that one goes well I'll start the other side - after I;ve patched up the holes in the boot area...

Ade

[vaughanmc]

Your cracking on with it mate

Once its done we'll need to get another meet organised :)

[ade]

I agree - hoping to have both arches and rear sorted by this weekend...

[vaughanmc]

Nice one mate

Mine could go with new arches as well, no point just now really - Just had the both rear 1/4 panels painted

[DW-Nova]

looks good mate, you've got a fair amount done recentley too hey, looks like good work.

[Adam]

Top skills Ade.
Its getting there :)


How come the thread title says "1.2sr" ? Lol

[ade]

Saturday 13/07/2008
Spent most of today skinning the outside of the rear arch.

Started by etch priming the inner arch and then once that weas dry I gave it a nice thick smear of seam sealant.

I then tack welded the outer arch in place.
http://img.photobucket.com/albums/v13/danga/DSC0001.jpg


I welded it in small sections and moved about the length of the arch to stop it warping-
http://img.photobucket.com/albums/v13/danga/DSc0003-1.jpg

Once this was done the grinder was put to work -
http://img.photobucket.com/albums/v13/danga/DSC0009.jpg

I used a welding joint called "butt welding" where you basically just butt one bit of metal up against another and run a weld down the middle, however my welding skills are still basic and my grinding skills although cautious need to be adjusted slightly to compensate for my welding. I had a couple of thin patches that needed further welding and I spent a fair amount of time shining a torch down the back looking for gaps and cracks.

The hardest part was the filler area - grinders can be brutal in difficult places-
http://img.photobucket.com/albums/v13/danga/DSC0010.jpg

I needed to cut away the extra metal in the middle-
http://img.photobucket.com/albums/v13/danga/DSC0011.jpg

This was then joined to the inner arch.

Later I etch primed the outside and left it to cure overnight ready for a skim of filler. no matter how hard I tried I did get a little but of warping - thankfully though it actually caused the new section to bow inwards just slightly meaning I have a perfect line to the arch lip ready to receive a nice flat skim of filler!

http://img.photobucket.com/albums/v13/danga/DSC0020.jpg

continued...

[ade]

I then started work on the rear. When I took the bumper off I noticed rust patches and a few holes. At some point in the cars history the rear end has been patched up and theres a few plates in the boot. Something I was aware of when I bought her. What I didnt know though was the person who did the job just welded straight over rusty metal and didnt seal it properly underneath. As such it spread...

Here's pics of the rust areas cut out (the green stuff is rust remover)-
inner arch (the one I'm working on)-
http://img.photobucket.com/albums/v13/danga/DSC0012.jpg

rear chassis leg under the rear light-
http://img.photobucket.com/albums/v13/danga/DSC0013.jpg

rear minus rusty areas -
http://img.photobucket.com/albums/v13/danga/DSC0014.jpg

http://img.photobucket.com/albums/v13/danga/DSC0015.jpg

http://img.photobucket.com/albums/v13/danga/DSC0016.jpg

http://img.photobucket.com/albums/v13/danga/DSC0018.jpg

this is the worst bit-
http://img.photobucket.com/albums/v13/danga/DSC0019.jpg

Also noticed a hole on the drivers strut mount-
http://img.photobucket.com/albums/v13/danga/DSC0021.jpg

http://img.photobucket.com/albums/v13/danga/DSC0022.jpg

They look far worse than they are - nowt a few plates and a bit more welding wont sort!

That's Sunday's task..

I also took a trace of the rear boot lettering and will get it drawn up properly ready for making transfers...

[vaughanmc]

Cracking work rate Ade

Hows the other Nova coming along ?

[ade]

it's on "hold"...

Gonna wait till I've moved house. once I've finished the white ones repairs I need to pay the wife some attention - shes made a few "comments" of late.

[ade]

Sunday 13/07/2008

I've got 1 day left after today to finish sorting out the current work on the SR. promised the wife it would be done by Tuesday 9although I'm off work Wednesday so can complete it proper then.

Here's the list of things I've got to do -

Last bit of welding
Make a patch between new arch and existing sill along the bottom (5 min job). Etch prime and seal ready for painting.

Front end
respray one of the wings after it got "knocked" :mad:
Prime and spray drivers inner wing after welding and paint passenger inner wing
Refit the radiator and fan
refill coolant
put coil, washer bottle back in place
reattach vin tags
fit lights
refit the wings and seal in place (fitting indicators and ariel in process)

Rear end
chassis black the underside around the newly sealed areas
Prime and spray white the interior welded areas

Arch
Trim back excess off lip and seal inner lip to outer lip
Drill hole for third screw on fuel filler
Chassis black and shutz the inner arch
chassis black the inside of the 1/4 panel
Waxoyl the inside of the outer arch (I cant get at the outer arch welds from the inside but need to seal it somehow).
Finish sanding and smoothing the skim of filler applied to level the old and new panels.
Speckle coat and check for low spots.
Level and seal with stopper
Remove all vynal to the door edge and along bottom
scotch the rear 1/4 panel
Remove rear window and treat small rust patch
Mask, prime and spray rear 1/4

Other tasks
Refit fuel filler neck
Replace fuel sender and return pipes (cracked and worn)
Reassemble interior (although this isnt essential just now)
Wash car
Move stuff out of next doors garage!

So not much then!

:eek:

[ade]

Sunday 13/07/2008
Here's what I did today.
In the garage for 8am and started by making templates for the new patch panels for the rear end.
An hour or so later here's the panels cut out-
http://img.photobucket.com/albums/v13/danga/DSCF0065.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0066.jpg

Here's the holes they need to fill (this pic shows plate one held in place) -
http://img.photobucket.com/albums/v13/danga/DSCF0067.jpg

In this pic there are 2 plates - 1 goes on the top and one goes underneath the rear light. They join to the chassis rail and then to theother parts of the car.

Hole from inside the rear arch-
http://img.photobucket.com/albums/v13/danga/DSCF0068.jpg

Heres the first plate held ready for welding -
http://img.photobucket.com/albums/v13/danga/DSCF0069.jpg

The top hole plugged-
http://img.photobucket.com/albums/v13/danga/DSCF0070.jpg

Heres the second plate welded in place-
http://img.photobucket.com/albums/v13/danga/DSCF0071.jpg

The next task was the rear holes on the bottom of the car. these were a biatch because the amount of sealer used initially kept catching fire - even though I thought I'd removed it!

First plate held in place -
http://img.photobucket.com/albums/v13/danga/DSCF0073.jpg

From the inside - a nice fit -
http://img.photobucket.com/albums/v13/danga/DSCF0074.jpg

Welded in palce - my welds are getting better - had some good runs on this one...
http://img.photobucket.com/albums/v13/danga/DSCF0075.jpg


continued...

[ade]

continued...

Then the other side was done. Both panels were welded from the inside aswell for extra strength. Here's both jobs complete-
http://img.photobucket.com/albums/v13/danga/DSCF0076.jpg

A coat of etch primer after they tops were ground off the welds to level them-
http://img.photobucket.com/albums/v13/danga/DSCF0077.jpg

Once dry the all the welds were sealed.
http://img.photobucket.com/albums/v13/danga/DSCF0079-2.jpg

I also repaired the small hole next to the front strut on the drivers side.

I then started on the filler. Started by applying a generous layer of paste all over the arch. It looks messy and theres more than I need but it'll be sanded back and levelled.
http://img.photobucket.com/albums/v13/danga/DSCF0063.jpg

I also finished off the fuel filler hole that needed a few more welds from the inside. this was a real biatch to do. It needs a skim of filler to level it but I'm pleased with the result considering the mess it was in before hand!
http://img.photobucket.com/albums/v13/danga/DSCF0078.jpg

Plan to get up at 6am tomorrow to get a good start. Based on the list above I think I;m gonna need to plan it carefully...

My knees are killing me from crouching down so much and my hands are really sore. I also seem to be covered in random burns, scratches and cuts... typical!

[Jeff16v]

Good repair work Ade:thumb:

[shy witness]

yopur not doing too bad there mate.

its very hard to just keep going on jobs like that for hours/days on end..


as you say............burns....sore knees...sore back......scratches...cuts etc etc....


usual all part n parcel.


irts hard work .....but u'll get there in the end

[AlexW]

I would love to pick your brains lol Seems yours is just like mine! All the same rot places. Top job! :thumb:

[draper]

good work and top write up ade, really imformative/helpful

[CorsaBBoomer]

I would love to pick your brains lol Seems yours is just like mine! All the same rot places. Top job! :thumb:

Can I joinj the club of the rot spot Nova's lol

Nice work Ade, love your documenting :thumb:

[ade]

Monday 14th July 2008

Got up early (6am) to start work on the car. had to get rear sorted today.

Started by sanding back arch.
http://img.photobucket.com/albums/v13/danga/DSCF0083.jpg
http://img.photobucket.com/albums/v13/danga/DSCF0082.jpg

Initially came out well but there were some high spots so I applied another skim of filler and sanding back. I then applied a layer of "stopper". This is basically cellulose putty which is like very fine filler (like very thick paint). you spread it on and it seals the filler (which is pourous and has pin holes of air bubbles in it which can cause problems with paint).
http://img.photobucket.com/albums/v13/danga/DSCF0099.jpg
http://img.photobucket.com/albums/v13/danga/DSCF0100.jpg

Whilst this cured I removed the rear 1.4 panel window. i notices a rust spot where the 1.4 frame had rubbed the paint.
http://img.photobucket.com/albums/v13/danga/DSCF0092.jpg

This would also make spraying the rear easier. the rust spot was treated.

Whilst the stopper cured I also changed the fuel return and sender pipes.
My old ones were badly perished -
http://img.photobucket.com/albums/v13/danga/DSCF0094.jpg

For reference the full sender is bigger then the fuel return (I think 6mm and 4mm diameter).
New ones in place-
http://img.photobucket.com/albums/v13/danga/DSCF0113.jpg

I then sanded the stopper back using fine wet and dry paper.
http://img.photobucket.com/albums/v13/danga/DSCF0103.jpg

The whole panel was then sprayed with zinc primer.
http://img.photobucket.com/albums/v13/danga/DSCF0107.jpg
http://img.photobucket.com/albums/v13/danga/DSCF0106.jpg

[ade]

continued...

I masked off the rest of the car leaving the rear 1/4 exposes and gave it several coats of white primer.
http://img.photobucket.com/albums/v13/danga/DSCF0108.jpg

To speed up the drying process I used a heat lamp
http://img.photobucket.com/albums/v13/danga/DSCF0118.jpg

Whilst this was curing i reassembled the engine bay area. i needed to refit the radiator, refill the coolant, reattach the lights as well as weld up the hole under the drivers strut mount...
http://img.photobucket.com/albums/v13/danga/DSCF0089.jpg
I also applied a little paint to the strut tops to make the bay look a little tidier.

Once the primer was cured I flatted it back using 800 grit and then applied some high build primer in some areas I wasnt happy with.
http://img.photobucket.com/albums/v13/danga/DSCF0110.jpg

This was cured further using the heat lamp and then a final coat of primer was applied.

Whilst that was curing I poked about uinderneath. I noticed whilst replacing the fuel sender/return hoses that there was a fair amount of rust hidden behind old underseal. I started to pick away...I wish I hadnt...
http://img.photobucket.com/albums/v13/danga/DSCF0120.jpg

there were holes!

I left these for now and
went back to sanding the final layer of primer back uwing 800 grit. I did these last couple of stages using the paper soaked in a dilyuted mix of hot water and washing up liquid. this helps keep the panel greese free and the paper clog free.
http://img.photobucket.com/albums/v13/danga/DSCF0115.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0117.jpg

The panel was then thoroughly dried and the area masked off for the final time.

I then sprayed the rear 1/4 panel using 3 full cans of glazier white.
http://img.photobucket.com/albums/v13/danga/DSCF0124.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0123.jpg

After a couple of hours and some seady application with the heat lamp the outcome was really good. It needs flatting back but I'm happy with the results...
http://img.photobucket.com/albums/v13/danga/DSCF0125.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0126.jpg

[ade]

continued...

I then had to reassemble the front of the car.

I carefully fitted the wings -
passenger
http://img.photobucket.com/albums/v13/danga/DSCF0097.jpg

driver
http://img.photobucket.com/albums/v13/danga/DSCF0098.jpg

making sure the front edges were sealed with the slam panel.

I then refitted the bumper
http://img.photobucket.com/albums/v13/danga/DSCF0128.jpg

I need to redo this because for some reason it wont sit flush the the ends of the wings (both sides) - the side clips are slipping for some reason...

I then sealed the gap between the inner and outer arches and applied a healthy amount of seam sealer all along the inside of the arch and down the join by the filler neck...

The next task is to sort out the rust underneath the car...those holes were right on the sill...

[ade]

Saturday 19th July 2008

This weekend I planned to cut out the rust and holes I discovered under the floor pan by the drivers sill.

http://img.photobucket.com/albums/v13/danga/DSCF0119.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0120.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0121.jpg

I removed the seat and carpet and it didnt look too bad from inside but I knew it was paper thin-
http://img.photobucket.com/albums/v13/danga/DSCF0001-1.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0002-2.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0003-2.jpg

In addition it looks like Vauxhall in their wisdom thought it'd be okay to shrimp on the rust proofing underneath...
http://img.photobucket.com/albums/v13/danga/DSCF0007-2.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0006-2.jpg

After cleaning off wehat was left of the rust proofing underneath to find good meetal and then cleaning up the inside to do the same I marked out the area to be removed -
http://img.photobucket.com/albums/v13/danga/DSCF0005-3.jpg

continued...

[ade]

continued...

I ensured the fuel lines were tied well out of the way (see above pics and red tie backs) and brought the grinder out to play

http://img.photobucket.com/albums/v13/danga/DSCF0011-2.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0010-1.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0008-2.jpg

I then made a card template and cut the new sections out of an old wing -
http://img.photobucket.com/albums/v13/danga/DSCF0009-1.jpg

After cleaning up and removing the paint I fettled it so it was a good fit. The new panel will be an l shape with the L section bonded to the sill, and the rest filling the gap - it will be seam welded to the top edge of the sill and around the existing hole then seam sealed flush from underneath after getting a good dose of etch primer.

One of the new panels fettled in place
http://img.photobucket.com/albums/v13/danga/DSCF0012-3.jpg

And then tack welded it in, fellting as I went to ensure a solid fit -
http://img.photobucket.com/albums/v13/danga/DSCF0013-2.jpg

By this time it was 6pm and time for Tea!

[ade]

Sunday 20th July 2008

More welding today - much to the disgust of the missus who made the comment - "I thought this car was rust free and was your daily runabout that you werent ever ging to mess with!"

I promised I'd be finished by 12pm so I could do stuff with her for the rest of the day - which would have been the case if I hadnt run out of wire mid way through!

:mad:lol

Anyway - managed to wangle more wire and finished the welding up -
http://img.photobucket.com/albums/v13/danga/DSCF0015-4.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0016-2.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0017-2.jpg

This was cleaned up, etch primed (inside and out) and seam sealed...
http://img.photobucket.com/albums/v13/danga/DSCF0019-4.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0020-3.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0018-4.jpg

Once this had cured ther outside and underside were painted with chassis black. prior to this the underside had been doused with rust remover
http://img.photobucket.com/albums/v13/danga/DSCF0021-3.jpg

All I need now is to shutz the underside and then check the passenger side - but thst can wait a week or three...

:p

[Rickyb]

top work matey :thumb:

[NovaLad]

No progress then??? lol

Coming on quick as per usual.

Keep up the good work.

[vaughanmc]

Good work mate

You bringing it along to the meet ?

[macc nova]

great work there pal, good luck on the underneath it looks pretty nasty!

[SKoob]

top work there, turning out to be quite a project lol I scrapped my SR with less rust than that, wish I could weld as i would be doing the same as you :thumb:

[novacabrio]

excellent work mate, good to see that people still belive in repairing rather than just giving up and finding a new shell

[draper]

good to see that people still belive in repairing rather than just giving up and finding a new shell

+rep, personnaly id rather repair what i have so i know its good than buy something else that will 9 times out of 10 need something doing anyway



more really good work ade, i know what you mean about running out of wire tho, i did last week then yesterday ran out of gas lol and it always seems to be when your making great progress

[DW-Nova]

some good work as per usual mate! yeh as said above it's good to see that someone is welding up as if everyone keeps thinking nah i'll get another shell theyre rapidly gonna run out. Ade have you been doing all the paint with spray cans ? hows it come out if so? how long do you think it's gonna take to be on the road then?

[Adam]

Awesome work Ade.

Good stuff for finding more rust and not letting it get you down, you just crack on with the welder :)

[ade]

some good work as per usual mate! yeh as said above it's good to see that someone is welding up as if everyone keeps thinking nah i'll get another shell theyre rapidly gonna run out. Ade have you been doing all the paint with spray cans ? hows it come out if so? how long do you think it's gonna take to be on the road then?

The cars on the road - it's my daily runner so HAS to be. Was only off for 5 days for the rear arches and that was because it was a bigger job than I had planned for.

Used spray cans for all the repair work and it came out really well. Some light orange peel effect but I applied about 3-4 coats so nothing a light sand back with 1000grit (wet) and then a good polish wont cure. It's white paint to 100% forgiving - the best colour (apart from jamaica yellow) for flatting back.

I'm SO glad I bought a welder before Christmas - best investment I ever made! The red project was good to practice on and I'd like to think my welds have improved 100% since the early days, Hardly blow any holes in the metal I'm welding. if I do I know how to handle them.

All I need to do to the SR is repair the other arch (although that's it's in pretty good nick at the moment just the inner arch is shot), fit GSi brakes, touch up some rust spots on the doors (outer skin chips mostly) and then finish shutzing the underside and arches. Then just waxoyl the whole thing ready for winter...

Hilariously my new arch actually buffy on my 14's theres so much lip! lollollol

[ade]

Awesome work Ade.

Good stuff for finding more rust and not letting it get you down, you just crack on with the welder :)

rust doesnt bother my that much now - as long as it's not one of the major chassis rails - actually look forward to it. the only bit that bugs me is that I need to get a bigger gas bottle and the missus moaning at me for working on the car and not spending time with her!

:roll:

[vaughanmc]

So its about done mate :)

You bringing it along to the meet ?

[SKoob]

the missus moaning at me for working on the car and not spending time with her!

:roll:

Happens to us all I think lol well mine certainly does too :mad:

[barkeybooster]

Nice work Ade! how did you attached the outerwing to the inner wing?

[ade]

outer wing is secured with bolts - 8 along the top, one on the bottom under the door, 2 inside in the footwell to pull the wing edge in (along the door edge) and 2 at the front to join to the slam panel at the front. before fitting I applied a nice bead of seam sealer all along the jpins to keep the water out!

[L14MNP]

Awesome mate! Don't let it die :) You remind me of me before the weight of thr world crushed my spirit and enthusiasm lol

[barkeybooster]

outer wing is secured with bolts . . . .

ok i feel stupid, i ment the rear arches . . . how did you attache the outer panel with the inner panel? it seems so hard to use a migwelder . . .

[ade]

I didnt weld the outer to the inner. I simply filled the gap with a decent seam sealer (greystripe). Both inner parts were etch primed beforehand and a good amount of chassis paint "poured" down the gaps to ensure its all sealed!

Inner arch was then sealed fully, chassis blacked and Sunday I'll be shutzing it all...missus permitting...

[vaughanmc]

lol Nice one Ade, cracking progress mate

[DW-Nova]

You didnt weld the inner and outer arches together? those spotwelds do provide a good bit of strength and rigidity to the car mate, you should drill holes and spotweld through them to tie it all together. How's the car going now? back in use as the daily driver?

[ade]

aye back in use - tbh I'll prob plug weld them however been advised that using a decent joint sealer (I used liquid weld) is just as effective as welding summut like arches. theres not that much force running through them and the very slight movement is catered for in the flexibility of the sealant I used

However see below re future plans...

[ade]

Sunday 27/07/2008
Gave the car a ruddy good clean inside and out today, fixed my speakers (werent working properly) after dissassembly the other week and cleaned the underside of my bonnet which was black with sh1te.

Also chassis blacked the rear arch ready for shutzing.

I'd stared to notice a strange whistling sound coning from my engine over the last week and traced it to somewhere around the alternator... a problem was a brewing...

Also took the time to make up highly accurate illustrations of the rear graphics (Nova 1.3SR) as well as take a trace of the Vauxhall Square badge off the front.

[AlexW]

Nicee

[ade]

Monday 28/07/2008

Went out to car this morning to discover battery totally flat so had to use the wifes Tonka Truck to get to work.

GRRR.

Thought about it at work and decided the alternator is probably shagged. Noticed over the last coupld of weeks the car really struggles to turn over 1st thing. Initially I thought it was the starter motor however a noise stared to appear - sort of a squealing nsound (like when the beslt slips) but not like that - more a repetative whistle.

Anyway - flat battery lead me down the alternatoir not working properly so I whipped it out this evening and stuck in a replacement one I had. Heavy duty GSi number too. Stuck my battery on charge for an hour or so during the change over and when I dropped it back in and tuurned the key it fired up instantly - no struggling or anything!

I'll see what its like tomorrow. Went round the rest of the car checking the earth cables - all fine.

Anyway - I mentioned I'd drawn some scaled pics of the rear boot graphics for the SR.

Heres massively scaled down version - Note the black is purely a fill colour.

http://img.photobucket.com/albums/v13/danga/novaweb.jpg

http://img.photobucket.com/albums/v13/danga/vauxweb.jpg

I've made a full panel inc the wiper hole (although this is smaller than actual to allow for positioning). the panel is complete with sections that wrap under the window and spoiler wrap. I'll be sending it off some time this week...

I've decided that once I get the other rear 1/4 panel welded up and fixed up a couple of other rust spots (nothing major just a few here and there on the body that need attention) I'm going to get the whole body resprayed. Sticking with Glacier white but a full respray will freshen it up totally - as well as make all the panels match! I'll get the bompers shot too in the original colour - the front one has several marke on it showing the original orange mold underneath!

Although my spray can jobs on the arches and rear look good theres a clear colour difference. I'm wondering if the cars not had a respray once before because the white is definately different. Theres more yellow in the panels I did as opposed to the original - could be age but white doesnt tend to fade...

Anyway - heres a couple of pics of the car all polished up. I've shopped it a adding full vynal on the bottoms and chaning my wheels so show them sprayed anthracite with silver rims.
http://img.photobucket.com/albums/v13/danga/test003.jpg

http://img.photobucket.com/albums/v13/danga/test002.jpg

I'll be getting the underside sealed up (with shutz) as well so I'll post prices later this week after I've spoken to the shop.

[vaughanmc]

Nice one mate, so she'll be at the meet ?

[ade]

yes - but with most of the vynal missing and the wheels as standard...

[vaughanmc]

Why worry mate :)

Its another Nova all the same

[Leeboo]

Loving this thread mate, replacing the front panel etc interests me.

It shouldn't take too much effort to get it to look like your photoshop!

[DW-Nova]

Looks good mate, so are you gonna go diy again or get the car professionally painted up? looks like a nice little car on the whole but i reckon it might look good lowered? is everything else standard?

[ade]

will get it professionally sprayed this time - theres a good body shop in my village (along with a sports car restorer - how random!) - he was supposed to come round this wevening to assess it but hes one of the village part time firemen so didnt show unfortunately (said he might not).

The cars totally standard except for the exhaust which I think is a performance system - not sure though - backbox isnt standard I knoe that - although I did get another "standard" brand new exhaust thrown in when I bought it.


At the moment I'm leaving the ride height as it is - the insurance is nice and cheap (£180 with zero no claims bonus and 8k limited mileage!). I think I'll wait a year before lowering it - although I am tempted to stick my weber on it!

[Gibbo]

looking good mate:thumb:

[dj_wudgey]

good work mate nice to see its nearly done!!

[ade]

Monday 04/08/2008
Bought myself a set of GSi discs and pads and some dot4 from the lovely halfords tonight - including a can of white primer, 3 cans of glacier white (for rear arch) and a poliching cloth spent over £100!

hate that place!

[vaughanmc]

lol Nice work mate

Will she make the meet :)

[ade]

yeah - will be there no probs.

Tuesday 05/08/2008
Removed the rear drums today to replace the bearings. had a lovely HUMMMMMMMMM coming from one of the sides - couldnt work out which so decided to replace them both. Theyre currently at a local engineering works waiting to get the bearing races driven out and new ones fitted.

Gonna remove the side vynal on the passenger side shortly ready for replacing the rear arch this weekend. Was gonna do it today but the missus convinced me to do it at the weekend - plus she wouldnt let me use the other car coz it's gonna be back off the road for a few days whilst I weld the arch.

typical...

[Riggy]

looking good fella , you need a halfords trade card mate , makes a massive difference lol

[Rexy]

I iz in da tradz clubz init.

[vaughanmc]

lol Good work Ade

Will be good to see it at the meet :)

[ade]

Tuesday 05/08/2008
Rear bearings all done today. Local engineering company by me replaced the inner bearing races (the sleeves that hold them in place) for £18 all in which I'm v pleased about. Didnt trust myself to do it properly.

Gave the hubs a wee freshen up (etch primered and will eventually paint them black) then fitted the bearings - one of the easiest jobs to do. Just need to make sure you dont overtighten the last nut to the washer can still move about enough without being loose.

Took her for a test drive and not a simngle annoying HUMMMMMMM to be heard!

Next job is to replace the passenger rear 1/4 panel - this weekends game...

[vaughanmc]

Nice one mate - I'm looking forward to some WIP pics :)

[ade]

was gonna do some pics for the bearings but tbh its so straight forward I may as well just post up the Haynes section on it...

lol

Almost finished the vynal - will post the full set scales down once done. I'd actually finished it earlier (was working on rear 1/4 vynal) but my PC decided to reboot midway through and the file corrupted with the work I'd done!

GRRR

[AlexW]

Good progress, i shall be watching this thread as i mentioned before, nice to see somone elses nova with the same rot and is doing the same work as i will.

[ade]

Saturday and Sunday 9th and 10th August.

The missus allowed me to repear my rear passenger arch this weekend - I had promised it wouldn't take more than 2 days - FAIL!

Looks like I'm using the 4x4 to get to work the next day or 2

I spent Friday evening removing the vynal and getting some horrible shutz crud off a repair patch that'd been welded in the bottom arch corner. Got her in the garage, part of the rear trim removed for panel access and on jacks ready for the morning.

Sarutrday 09/08/2008
The actual outer skin wasnt too bad but I knew from feeling under the lip that the inner arch weas shot. Plus theres this patch in the corner -
http://img.photobucket.com/albums/v13/danga/DSCF0002-3.jpg

I didnt want to take much metal off as the outer skin wasnt too bad so I cleaned off the paint and parked out my cut line -
http://img.photobucket.com/albums/v13/danga/DSCF0004-5.jpg

Here's the mess behind that corner piece - I'll need to do some inner repair work I think -
http://img.photobucket.com/albums/v13/danga/DSCF0007-3.jpg

I then cut the outer skin off (after drilling out the spot welds). As predicted the inner arch was shagged.
http://img.photobucket.com/albums/v13/danga/DSCF0008-3.jpg

I then cut this off level with the outer skin.

I then offered up the new outer skin panel and from the inside arch drew on the back of it folowing the line I'd cut. I then cut this out and offered the new cut panel to the car -

http://img.photobucket.com/albums/v13/danga/DSCF0003-3.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0017-3.jpg

I now needed to rebuild the inner arch. This was a bit more work than the drivers side as the bottom edge was missing. I started by using another outer skin and cutting and chaping it to fit snuggly to the inside of my other panel that makes my outer replacement skin. This was then offered up in sections and welded in place to the inner arch edge -
http://img.photobucket.com/albums/v13/danga/DSCF0012-4.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0013-3.jpg

continued...

[vaughanmc]

Nice progress Ade :)

[ade]

continued...

Sunday 10/08/2008
Finished off the inner arch - had to repair the bottom corner as it was missing or rotten - this included som of the inner structure...in progress -
http://img.photobucket.com/albums/v13/danga/DSCF0011-3.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0014-3.jpg

I then started to weld up the outer skin - this was a nightmare. For whever reason my welder just wouldnt weld properly or summut would go wrong! The weld just wouldnt flor - it was like a bad earth - odd thing was when I moved to the inner arch for test it the weld was fine?!?

:mad:

Then it went really bad - started by welding the wire to the bit - tried to remove the bit after freeing the wire and it jammed. Used mole grips to remove the bit and the thread snapped in the end of the gun!!!

:eek:

Had to drill the fecker out.

Lost an hour ar$ing about and finally started again but for whatever reason the weld just wouldnt flow - then after another hour messing about (and running out of gas!) it started to weld properly. By this time though I'd managed to get a coupld or warped spots in the panel!

Anyway - they werent too bad and I'd have to skim the skin anyway so with a careful bit of doly work I'd be able to lower the high points and smooth it out...

Outer arch "mess" - (looks worse than it is)
http://img.photobucket.com/albums/v13/danga/DSCF0020-4.jpg

I then drilled holes in the arch lip to plug weld the inner and outer skins together.

Ground these back and then gave it a coat of etch primer -
http://img.photobucket.com/albums/v13/danga/DSCF0021-4.jpg

you can see the ripples in the panel!

Once this cured I gave the inside arch a good wad of seal sealer making sure the inner arch, inside the car and in the cavity areas was well packed.

I then gave the outer skin a skim of filler. This was sanded back. By now it was 10pm and I'd been on the go since 7am and feeling a tad tired.

I applied a final layer of filler to level it off completely ready for final sanding Monday morning.
http://img.photobucket.com/albums/v13/danga/DSCF0023-2.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0026-3.jpg

I'm working 12-8 tomorrow and will sand flat tomorrow morning and apply a final layer of cellulose stopper. Then in the evening I'll sand this back and prime it ready for final sanding and top coat Tuesday morning (Hopefully!)

lol

[ade]

I'm hopeful this is the last of the big welding jobs I need to do. Although I've not checked under the passenger carpet yet...

[vaughanmc]

More quality work Ade :)

So she'l be at the meet for definate ?

[brainsnova]

:thumb: works looking good mate. Top job

[ade]

Vaughan - yes she'll be there - need to de vynal and doors though as she looks odd with just the doors in vynal!

[vaughanmc]

Nice one mate - Will be awsome to see it all tidied up

Looked good at PVS though

[DW-Nova]

Lovely bit of work as per usual mate, nothings easy though hey. looks nice though and fair play for keeping at it, might have found myself another nova today too, should be concentrating on my project but found an A reg brown SR with a snowplow front end.

[ade]

cool - A reBrown nova with a snowplough front end? The reason I got into Novas in the 1st place was due to a brown a reg nova hatch with a snowplough nose! Went out with a lass at Uni for over 2 yrs and she had the exact same Nova! brings back amazing memories! - especially the one when some bint reversed her fiesta into us at a junction aftrer hitting the wrong gear and the snowplough totally wrecked the back of her car! Caved the boot in but did feck all to the Nova!

I think the reg was A113 NHG?

[ade]

Monday 11th/Tuesday 12th and Wednesday 13th August.

Been working back shift this week (12-8) so been getting up early to work on the arch, then coming in after shift and doing more work - totally shattered!

Anyway - over the last few days (for a couple of hours a night) managed to smooth the filler down and applied a nice even layer of cellulose stopped.
The next day this was sanded smooth and touched up - with it being further sanded down once cured using 400 grit wet n dry (dry).
I then sprayed the whole panel with etch primer. This was then flatted back with 800 grit and a layer of filler primer was applied to remove any blemishes -

http://img.photobucket.com/albums/v13/danga/primer2.jpg

http://img.photobucket.com/albums/v13/danga/primer1.jpg

This was flatted back the next day (Tuesday) and a final topcoat of white primer was appied ready for painting that evening -

http://img.photobucket.com/albums/v13/danga/primer3.jpg

I've been spraying the panels I've been replacing with Halfords Glacier White paint and have been fairly happy with the job to date - It's not perfect but then it doesnt matter because I intend to get the exterior of the car resprayed anyway. however this last wing was an absolute balls up when I came to spray the top coat on that evening.

I managed to flat the final white layer back fine - used 800 grit applied wet with soapy hot water and it was a really good finish. I dried it off using a heater to get the panel nice and warm and degreased it fully.

I shook my 3 cans well and as always sat them in very warm water the loosen the paint up to make it flow better.

But when I can to spray it I swear the 1st can was filled with water! The minute the paint touched the panel it was like the panel was soaking wet! beads of water appeared on the panel and ruined the job!

I stopped and checked the panel thinking condensation but it was dry on the arreas I'd yet to spray?!?

Anyway - after getting annoyed I waited for the paint to flash over and then used a heat gun to finish it off - wet sanded it back and started again.

the second can wasnt wet but for whatever reason the paint went on like a fecking zebra! It's supposed to be white so why do I have grey streaks in it!

AHHHHH!

Let it flash over than turned to the final can which I'm pleased to say was fine - however although it covered the panel I can still see the zebra stripes through it when you look at a certain angle.

Oh well feck all I can do about it - the main thing is the rear panel is finished and until I check under the passenger side carpet so's all my main welding jobs! the arch is all sealed up and the inner arch is chassis blacked for protection until I can shutz it.

This morning I reassembled the car and after finishing off a bit of chassis black (which I got all in my hair and on my right ear!) she went back to being my daily runner...

much to my wifes delight!

Ended up having to T-Cut my head to get the fecking paint out of my hair though!

[AlexW]

Great progress as usual. That arch really does look like mine, damm i think mine and yours were seprated at birth lol Mines even got some Sr stuff as standard too.

[SKoob]

Looking good as usual Ade, I've been using Upol aerosols from a body shop suppliers and found them to be excellent for consitancy and match, might be worth seeing if theres anywhere similar in your area. Probably a bit cheaper than halfrauds too lol

[vaughanmc]

Upol is really good stuff - Used there products many times before :)

[ade]

not too bothered really coz it'll get resprayed soon anyway...

[ade]

Saturday 16/08/2008
Spent most of Saturday morning remog the last remaining vinyl panels off the side of my car. I'd already removed the wing and rear 1/4's through rebuidling these areas...

Removing vinyl (or however you spell it!) is pretty easy - just time consuming. This stuff's been on the car over 20 years!

To start you need a heat gun, plastic scraper, some rags, t-cut and super resin polish (or equivalent). You could also do with a sharpish long blade serated edged knife to help remove the bump strips.

Bump strip removal is pretty easy - mine were held in place with 2 foam strips - simply insert the knife between panel and bump strip and grip and cut - once your an inch or so in carefully take the end and as you cut pull back - if youre careful the strip will come away without damaging the panel or the aluminium strip behind - allowing you to r-use it (I'm reusing all of mine).

Once removed youre left with this -
http://img.photobucket.com/albums/v13/danga/DSCF0001-3.jpg

http://img.photobucket.com/albums/v13/danga/DSCF0002-4.jpg

Next task is to start removing the vinal. Start from insuide the car and using the heat gun warm the edge overlaps. Keep the gun moving. Once its hot start to peel it back with your fingers (be careful its hot!). you might need to use the scraper to losen the edge a little. Once you get a routine you'll see itpeel back easily - ewhen it resists the glue has taken hold again so heat it up.

Once the edges are removed start on the outside. Star on one ot the tops below the lock for example and using the heat gun to warm a section - I did it in strips starting from the top corner to the bottom of the door at about 5" sections. Once warmed through - hot to the touch, pick a corner and carefully pull away.

Now - if you;ve warmed too much the glue will separate from the vynal and stay ont he panel (a pain in the anus!). if your good then youre glue will come off the panel leaving it clean and bare! once you feel the vinal resist heat it some more. You'll notice when you do this that the section removed will shrink and may tear - if so - use the scraper to get a cover to pull from.

Once removed youre left woth something like this -
http://img.photobucket.com/albums/v13/danga/DSCF0004-6.jpg

Sections of clear paint and glue that got left behind.

Now for the heard part - removing is easy but time consuming.

Start by heating up the glued area by wafting the gun over it-
http://img.photobucket.com/albums/v13/danga/DSCF0005-4.jpg

Then using a cloth over a finger start to pull the edges of the patch in to the centre -
http://img.photobucket.com/albums/v13/danga/DSCF0006-3.jpg

the glue will pull like this -
http://img.photobucket.com/albums/v13/danga/DSCF0004-6.jpg

Work around the edges till youre left with this -
http://img.photobucket.com/albums/v13/danga/DSCF0007-4.jpg

Now I need to remove the remaining foam from the door -
I start by using the heat gun to heat up the remaining foam and then using a scraper scrape off the foam top leaving the glue underneath (this is easier than trying to remove it in a oner).

I then start to heat the glue strip and use the cloth to pull it along and off -
http://img.photobucket.com/albums/v13/danga/DSCF0009-3.jpg

leaving this -
http://img.photobucket.com/albums/v13/danga/DSCF0010-2.jpg

the next stage is to cover the lower section in t-cut and leave it for 5 mins to break the glue residue down. Then get a cloth and buff it off. It will take a couple of passes and you may need to use the gun to soften the more stubborn areas -
After one pass -
http://img.photobucket.com/albums/v13/danga/DSCF0011-4.jpg

After another pass -
http://img.photobucket.com/albums/v13/danga/DSCF0012-5.jpg

I then covered the whole side of the car in t-cut to cut the faded paint back a little to mnatch the pristine lower section thats been protected.

Once applied i left it for 5 mins and then applied a wad of super resin polish and rubbed this in. I then sprayed water on the side of the panels and applied more resin polish onto a lambs wool mop attached to the end of a drill and simply polished away - being very careful on the edges of panels and curves. the amount of dirt that came off was amazing!

heres the finished side -
http://img.photobucket.com/albums/v13/danga/DSCF0015-5.jpg

You can see how the replaced panels and door are different colours - hence the need for me to get the car resprayed (what an excuse!)

[ade]

I then repeated th eprocess on the other side -

http://img.photobucket.com/albums/v13/danga/DSCF0017-4.jpg

and
http://img.photobucket.com/albums/v13/danga/DSCF0019-5.jpg

I left the recently painted back passenger panel - needs to harden more plus I may repspray this to hide the dodgy finish!

[stevenf]

some nice work there mate :thumb:

[Sturge]

If you ever try removing viyl again ade, get yourself some bug and tar remover, or tar and glue, or whatever the hell they call it these days, slap plenty of it on, leave for a few minutes and just wipe off!

[brainsnova]

i done this to my 1.3sr years ago along the sides and the left over glue came of easy with fuel

[vaughanmc]

Nice one mate - Good to see you again today at the Wheel

One day...That car park will be full of Nova's lol

Car looked mint as well - If you get a message from Greg about the interior I'll go down with you if you'd like :)

[Dave.]

looks good ade.. them doors are in suprisingly good condition

as said before.. if you get b pailler vynal made id be interested in a set only if your going to get afew made tho.. not just for me lol :thumb:

[DW-Nova]

By far the eaiest way to take off the glue left by the vinyl/ bump strips it to use cellulose thinners, it sounds brutal but it dosnt do any harm at all, just whipe it on ( use a fair bit) then wash it off with a bit of soapy water, saves alot of time and wont damage the paint at all!

[ade]

By far the eaiest way to take off the glue left by the vinyl/ bump strips it to use cellulose thinners, it sounds brutal but it dosnt do any harm at all, just whipe it on ( use a fair bit) then wash it off with a bit of soapy water, saves alot of time and wont damage the paint at all!

now - I disagree - and the reason depends on what paint you have on your car. If its 2pak - no problemo - if its cans...god help you!

celly thinners is brutal to canned paint - or celly based paint. I know - I used the stuff initially to remove the vinyl on the rear 1.4's

lol
:eek:

[ade]

Nice one mate - Good to see you again today at the Wheel

One day...That car park will be full of Nova's lol

Car looked mint as well - If you get a message from Greg about the interior I'll go down with you if you'd like :)

cheers - not heard from Greg yet - might send him a text. I've pm'd him but no reply. I've give it to tomorrow before I start stalking him.

[vaughanmc]

lol Well he phoned me last night and I told him you were interested in the interior so he does know you want it!

I'll speak to him sometime soon no doubt and get some more details from him

[ade]

Anniversary Weekend - Billing 24th August 2008
Decided to change my brakes to the uprated GSI spec ones using Corsa GSi calipers (the ones with the springs - mini ATE's).

The PNG rallied round and did the whole lot in 45 mins inc servo!

The difference is unbelievable! Such an improvement and no judder!

Friday 30/08/2008
Took car to garage for full service and MOT. They did a full service but decided not to do the MOT as they couldnt adjust the front drivers headlight - the replacement slam panel I fitted was 10mm too far back pulling the bottom of the light too far back. Also there was a bracket at the bottom of the engine that bolts to the exhaust that'd sheered off and needed welding. Also they adjusted the idle and she feels more responsive although they still need to check timing...

Took the car back, drilled 2 new mounting points and refitted the clips. the adjusters had seized so I freed these and realigned the light manually - much improved! 5 minute welding job fixed the bracket and the cars ready for MOT on Monday - just gotta drop her back off at the garage. They've already said there shoud be no issues MOT wise.

[Cheeze]

sounds like you are getting there Ade, How is the other one getting on?

[ade]

other ones on hold till I get a bigger garage...got too many other projects on the go at the moment and works a biatch just now...

[DW-Nova]

Alright there mate, hows both the cars doin? not seen an update in a while hey, best of luck.

[ade]

Saturday 01/11/2008

God its cold!
Been dry the last few days so I thought I'd give the car a wash and pump the cavities full of waxoyl.

Took a a couple of hours but the SR's now full on the wonderful yellow gunk and absolutely reeks inside of waxoyl vapour!

The only bummer problem was one of the C clips that hold on the window winders pinged off into orbit! I heard it land in a bush nearby but have no chance of finding it!

So if anyones got a spare let me know!

[DW-Nova]

Good stuff, really important to rust proof these cars hey, as i'm sure you'll know they dont need any encouragment to rust anymore. Are you still going to go for the re-spray or just drive on ?

[ade]

respray. Although need more garage space.

[dj_wudgey]

looking spot on matey that is!!!

[DW-Nova]

DIY re-spray then ade ? hows the car going in general ?

[ade]

buying an hvlp sprayer in a week or so then its just getting the time to do it!

[DW-Nova]

Sounds good, i've always liked the idea of those hvlp sprayers so will be interested to see how it all comes out. good luck.

[Joe Richardson]

Just read through the whole thread:cool:

some work gone on there Ade,looks mint now what you have done:thumb:

Kept another SR on the road:D

[dj_wudgey]

buying an hvlp sprayer in a week or so then its just getting the time to do it!

nice ade glad to see your not finished with it yet!! well hope you get it painted soon will look even beter!! looks spot on any way matey!!:thumb:

[16v Nova Kev]

good work ade i need to the back arches on my gte too. i will need to come up a run one night

[dj_wudgey]

hows the sr then ade finished it yet dude???

[db_1.2]

This is a bit worrying. This is the first time i seen the car, however, the other night i dreampt about the same car! Well, it was brand new, and had compomotives and twin carbs!

Very nice car! Things that dreams are made of!

[blue_peg_16v]

hows the sr then ade finished it yet dude???


were you just off your tits at pv it was there

[dj_wudgey]

yea i know but it didnt have grey vinyl at the bottom off the doors so id class that as finished lol

[ade]

lol - the SR's a run about and it wont be properly finished until I've taken it off the road and stripped it down and given it a proper respray.

At the moment she's doing okay - although the current winter weather is seriously taking its toll! Have LOTS of little rust spots all over where stone chips and gritters have abused the lower side of the car - these will be sorted in the future...my main focus just now is my other project and once thats done I'll do the SR "properly".

Heres a pic of her over the winter...
http://img.photobucket.com/albums/v13/danga/bonnet2.jpg

And heres one after I'd applied the lower grey panels (its sprayed not vinyl)
http://img.photobucket.com/albums/v13/danga/sr5-2.jpg

[vaughanmc]

Looks very cool Ade :) Nice to see you use it all the time as well :thumb:

[NovaLad]

Sexy!
And so is the car ;) lol

[ade]

Sexy!
And so is the car ;) lol

lol you tart!

[Nova_Tek]

Dunno how I missed this project, only just stumbled upon it. Some great work there mate. Looks like you had plenty to do and you kept getting surprises by the looks of things. Great to see the SR being used as a daily.

Good work :thumb:

[novaload1992]

i love it, great car very clean looking

[dj_wudgey]

good to see she's doing ok mate and glad to hear its getting a respray aswell matey looks top now its got the vinyl on though dude!!!

[dj_wudgey]

that vinyl looks a pretty good if you used the grey one from the club shop which i gather you did ill be getting a set for mine very soon!!!

[ade]

its not vinyl its paint! I started by rollering on a layer of primer to get the "bobbled" effect, then sprayed on rover hurricane grey followed by a light dusting of matt black to take the shine off. I then redusted "badly" with hurricane grey to give it a matt orange peel effect - came out really well all trhings considered but yes I will be getting the "proper" vinyl from the club shop in the near future...

[dj_wudgey]

its not vinyl its paint! I started by rollering on a layer of primer to get the "bobbled" effect, then sprayed on rover hurricane grey followed by a light dusting of matt black to take the shine off. I then redusted "badly" with hurricane grey to give it a matt orange peel effect - came out really well all trhings considered but yes I will be getting the "proper" vinyl from the club shop in the near future...

ohh yea looks well mate!! im getting some vinyl soon but i think for the show season im going to use some off that u-pol paint that medium grey well i think thats close to what nick j used on his so ill go for that untill i have the respray done on mine after the shows!!! but it looks **** hot that ade!!!

[ade]

small update - The SR's engine has died - revs seemed to jam open for a short period - bounced off rev limmiter and is now knocking mega badly (misfire). Currently in the garage...

Have managed to source another engine courtesy of Ian off of here but a mega pain in the butt hole!

[dj_wudgey]

get it sorted mate i know its a pain but she's worth it!!! the sr is a stunning car so get her done matey!!

[ade]

just had report from garage - no 4 piston is down and its blown the head off the spark plug!

major failage!

Think I'll be fitting a new engine - faster and cheaper - prob have a go meself...

Ade

[AlexW]

Did i hear a C20XE :p lol

How many miles has that engine done, usually go for million of miles lol

[Damo]

Gutted for you ade but come what may mate hope the new engines a good one though.

Keep the updates coming.

[Mazz]

I would say get a E16 in there, but that means new fuek tank etc - so another 1300 might be easier..

[Southie]

Bad luck on the engine Ade. :( Keep it 1.3 ;)

[craig green]

Atleast you dont need it for work, sorry. :)

Lots of time on your hands to fix her.

[dj_wudgey]

Bad luck on the engine Ade. :( Keep it 1.3 ;)

you know that is the only option thats worth while lol

[ade]

yes its keeping the a 1.3 in it. Ian (Nov4sport) has a "spare" SR engine hes selling to me and we're fitting it this Sunday - expect pics!

[craig green]

Are you taking the car to him or is the engine coming to you?

[muzzy]

This is a really nice looking car, well done on keeping it 1300 too :cool:

[ade]

cars at the garage down the road from me - were taking it back to mine and swapping the engine over in my drive - no room in the garage what with the Puntova build stuffed like a hog roast on a skillett!

lol

[dj_wudgey]

lol get it done fella!!!

[ade]

Sunday 14th March 2010

Ian (Nov4sport) kindly lent me his services for the day to perform and engine rebuild and swap - in one day...

I collected a spare engine from his gaff on Friday - however I didnt realise it was in 3 sections (head, cam box and bottom end) - so (he) spent a frantic Saturday gathering gaskets and bolts and lube to help rebuild it!

I was givben the task of cleaning up the block which was a tad rusty -

before
http://www.modelnovas.com/images/engine80.JPG

http://www.modelnovas.com/images/engine81.JPG

http://www.modelnovas.com/images/engine80.JPG

after an hours worth of wire wool and wire brush attachments - being careful not to damage the top. Also cleaned up the corwns but you cant se them...
http://www.modelnovas.com/images/engine82.JPG

http://www.modelnovas.com/images/engine83.JPG

The SR - towed back from the garage - looking sorry for itself. The garage advised compression was down on 3 pistons and no4 piston had bent the end of the spark plug!
So - after draining the coolant we set to work removing bits - Ians initial idea was to remove the enigne with shafts still connected to the gear box but after we discovered the long shafts cv boot had totally split we removed that shaft making it easier to get the engine out in the long run...
Started with split pins from the front hubs slackening off the 30mm hub bolt as well -
http://www.modelnovas.com/images/engine3.JPG

http://www.modelnovas.com/images/engine4.JPG

http://www.modelnovas.com/images/engine5.JPG

we then losened off the rear mounting bolts from the engine (not the chassis) - more fiddley but made getting engine out easier.
http://www.modelnovas.com/images/engine6.JPG

http://www.modelnovas.com/images/engine7.JPG

[ade]

Ian then "dismantled" the gear linkage - rather than undo the geat selector rod from the linkage - the theory being that it would be easier to reassemble and also wouldnt cause problems trying to set the gears up again - which proved to be correct!

http://www.modelnovas.com/images/engine10.JPG

http://www.modelnovas.com/images/engine13.JPG

Other anciliaries were disconnecteed from the engine (hoses, rad fan was removed etc). Although the rear suspension mouints were losened we couldnt remove them due to lower exhaust pipe getting in the way so the manifold came off
http://www.modelnovas.com/images/engine18.JPG

revealing a seriously oily no4 exhaust port.
http://www.modelnovas.com/images/engine20.JPG

with the rear mount free and the bottom of the engine supported the drive stafts were removed from the wheel hubs - which were removed from the suspension (someone at ther national day made damn sure the bolt were on v tight!)
http://www.modelnovas.com/images/engine23.JPG

the split CV joint
http://www.modelnovas.com/images/engine26.JPG

The engine was then "secured" to the engine crane and the front engine mounts were then losened off -
http://www.modelnovas.com/images/engine29.JPG

http://www.modelnovas.com/images/engine28.JPG

Ian delves deep into the unknown!
http://www.modelnovas.com/images/engine30.JPG

the engine is free!
http://www.modelnovas.com/images/engine31.JPG

[ade]

fumes go to Ians head!
http://www.modelnovas.com/images/engine33.JPG

and in the removal the radiator caught a glancing blow!
http://www.modelnovas.com/images/engine34.JPG

Thankfully the core isnt damaged - just scuffed! One emply engine bay
http://www.modelnovas.com/images/engine35.JPG

Ian lands a 100lb engine with some dodgy blue nylon rope!
http://www.modelnovas.com/images/engine37.JPG

The next task was to start removing bits off the old engine to go on to the new one. Starter motor came off and moved over
http://www.modelnovas.com/images/engine38.JPG

followed by the alternmator, timing belt and oil breather box (which was full on mayonaise and needed a wee petrol bath)
http://www.modelnovas.com/images/engine40.JPG

The inlet manifold was next with weber carb
http://www.modelnovas.com/images/engine44.JPG

The geaqr box was next - the bolts were removed
http://www.modelnovas.com/images/engine47.JPG

and only a tiny amount of trnasmission fluid escaped!
http://www.modelnovas.com/images/engine50.JPG

http://www.modelnovas.com/images/engine52.JPG

[boyle_46]

looking good Ade some good progress made there , keep it up :D

[ade]

the new engine was assembled -
http://www.modelnovas.com/images/engine53.JPG

and the gearbox went on with no problems at all!
http://www.modelnovas.com/images/engine54.JPG

http://www.modelnovas.com/images/engine55.JPG

water hoses were next
http://www.modelnovas.com/images/engine57.JPG

and Ian was particularly proud at the was the gearbox cover plate scrubbed up!
http://www.modelnovas.com/images/engine58.JPG

Because the cam belt was being changed we changed the water pump too. 1st we removed the cover, the the old water pump which came out without any probs. A new pump was fitted losely - this would be tightened once the cam belt was in place as it helps tension the belt.
http://www.modelnovas.com/images/engine60.JPG

water pump in place with newly added alternator
http://www.modelnovas.com/images/engine62.JPG

The head was then fitted. Gasket was fitted and then hear placed on top. The rocker bits were all compressed and oiled
http://www.modelnovas.com/images/engine63.JPG

http://www.modelnovas.com/images/engine65.JPG

Then the snall collets and rockers themselves were put in place
http://www.modelnovas.com/images/engine66.JPG

[ade]

Ians missus then turned up to watch!
http://www.modelnovas.com/images/engine69.JPG

After a beam of sealer was applied, the rocker case was then fitted and new head bolts tightened up "losely"
http://www.modelnovas.com/images/engine71.JPG

Each one was then tightened to the correct torque and to the correct number f turns in the right sequence
http://www.modelnovas.com/images/engine72.JPG

The cam belt was then fitted with the engine set to Top dead centre and both cam and bottom end markers lined up perfectly!
http://www.modelnovas.com/images/engine73.JPG

the cam cover was then bolted in place with its gasket
http://www.modelnovas.com/images/engine74.JPG

The engine was now ready to go back in the car - it was trussed up and raised on the engine crane...
http://www.modelnovas.com/images/engine76.JPG

To protect the radiator we also fitted some board as a precaution. Because we had to set the engine at a sharp anglke to get the short drive shaft in place correctly 2 planks of wood were used so the bottom of the engine could rest lightly on the tie bars
http://www.modelnovas.com/images/engine77.JPG

At this point I'd qoite haynes and say refitting is the reverse sequence of removal excep that there was much swearing, trapping of hands and moch wiggling bet eventually it went in to place - engine mounts were rebolted and a new CV jpint fitted to the drive shaft (we actually changed a split joint on the short shaft and I just swapped the long shaft for a spare I had saving much time)

The engine was replumbed/wired and rethingied and all was ready -
http://www.modelnovas.com/images/engine78.JPG

HOWEVER - as you can see from the pic the battery was (strangely) devopid of enough juice to get her to run however after much cursing of wires and HT leads at the coil end we did get a good spark from the plugs and fuel was coming in the carb - but the batery just wasnt strong enough to fire the engine - she did however turn and sounded healthy!

So I wont know if she'll run until Monday.

I'll let you know!

[ade]

Just a quick word to say BIG THANKYOU to Ian who without his "donation" of the engine, sourcing of bits for engine and spending over 12 hours from 9.30am until well past 10pm doing pretty much all the major work I wouldnt have a "new" engine in place and would be several hundreds of pounds worse off!

Cheers matey!

[Dave.]

Hopefully she'll fire into life Ade! :thumb:

[ade]

she'd better or my missus will be demanding a replacement...

She thinks I should buy a Landy!

[brainsnova]

course its going to fire up and run perfect after all it a vaux :thumb: landys just rust quicker

[Novaboi_1991]

course its going to fire up and run perfect after all it a vaux :thumb: landys just rust quicker

Is that possible? :wtf:

Looking good ade, be sure to video the first turn of the key. hope it starts up ok.

[ade]

started her up and she runs fine!

However cant get any gears as the clutch cable needs adjusting and she wont hold revs - so need to adjust choke and timing a little but at keast the old girls breathing again!

[vaughanmc]

Good work Ade & Iain :)

[novalovingned]

she'd better or my missus will be demanding a replacement...

She thinks I should buy a Landy!

I hated landys until a few moths ago until my boss gave me his 55 plate TD5 for the winter. The things amazing lol never even had to use the diff lock going up hills from a standstill in 2 foot of snow! Awesome bit of kit.

Good progress on the engine though. Sure it will fire up fine :)

[NOV4_SPORT]

Just a quick word to say BIG THANKYOU to Ian who without his "donation" of the engine, sourcing of bits for engine and spending over 12 hours from 9.30am until well past 10pm doing pretty much all the major work I wouldnt have a "new" engine in place and would be several hundreds of pounds worse off!

Cheers matey!

Its all good mate, always happy to help out, we are even now after you stayed at the services with me when the sport refused to start up on our way to billing lol.

9.30 am - 10pm, helped along by unlimited coffee, smokes and chicken dinner

iain :thumb:

[sport]

Well done lads.

[NOV4_SPORT]

you cant beat a bit of a mince about on a sunday lol

iain

[craig green]

Nice work, good photo journal of the events also.

Its probably a godsend this happened when it did Ade (ie prior to the national) & not somewhere on the side of the road between your place & Derby!

[Adam]

Good work lads, good to hear the new engine fired up, theres not a lot to stop a 8v carb engine from firing up really!!!

Good pics too Ade

[Lee]

theres no a lot to stop a 8v carb engine from firing up really!!!



BAAAAAHAHAHAHAHAHAHAHAHAHA lollol

[Adam]

:confused:

[Lee]

:confused:

It wont start, just been on the phone with him lol

Electrical fault by the sound of it.

[Adam]

lol lol

Oh, err. Read a few pages back it was running fine???

[novalovingned]

lol lol

Oh, err. Read a few pages back it was running fine???

Yeah but it is a nova were taliking about :)

[ade]

lol - aye the fecking thing seems to have developed a intermittant electrical fault somewhere around the ignition area!

Turn the key and the fecking wipers come on! lol

Anyway - gutted the dash and other interior bits looking for broken wires - nothing - put it back together and she now runs fine!

Been out a few times in her and all okay - although when I start her up or if I flash my main beams with lighhts off the wipers come on for some reason!

Reckon its a faulty relay. Will remove and tinker when I get 5 mins...

[dj_wudgey]

well mate hope you get her sorted!! she's a beaut little car!! well i say that about all mk1 sr's lol

[Danny s-p]

hi ade wot back box have you got on it. it look really nice i may get one for my GTE .

danny s-p

[dougie_boi]

lol - aye the fecking thing seems to have developed a intermittant electrical fault somewhere around the ignition area!

Turn the key and the fecking wipers come on! lol

Anyway - gutted the dash and other interior bits looking for broken wires - nothing - put it back together and she now runs fine!

Been out a few times in her and all okay - although when I start her up or if I flash my main beams with lighhts off the wipers come on for some reason!

Reckon its a faulty relay. Will remove and tinker when I get 5 mins...
ive had this as well mate turned out it was the earth that comes off the loom at the passenger side head light im sure it bolts onto the chassis leg mate