Mk1 Small Block Road Rally/Hillclimb Car

Decided to start a new project thread for my Mk1 as i have been too undecided about which direction i wanted to go with it. Anyhow I have made my mind up to just use it as a motorsport and track car, hopefully building it just to compete in road rally events and the occasional hillclimbs and trackdays with very little road use.

I haven't put much thought into the engine spec as i want to get all the shell prep done first, but is most likely going to be a 1400 8 valve to keep within the regulations for the above motorsport disciplines.

I'm hoping to build it into a competitive little car but keeping within the regulations laid out in the MSA Blue Book for both sports, which prohibits the fitting of things like bias pedal boxes and rose-jointed suspension setups, so I will really be aiming to get the most out of the original Nova layout.

Anyway the first task is to get all the bodywork sorted and any other bits and pieces that need welding or cutting. This will include brackets and spreader plates for the cage, seats and harnesses etc.

A few pictures as it stands now:

http://i669.photobucket.com/albums/v...reFrontEnd.jpg
http://i669.photobucket.com/albums/v...ld/BackEnd.jpg

The engine bay has been completely stripped now with the exception of the gearbox which i put back in as part of my Cavalier internal shifter conversion.

Overall the shell is still a good one, but it has a few bad bits:
Front panel around the headlights (passenger side has already had some attention
Rear chassis rails need a couple of plates but still good
Passenger side sill has a 2 inch hole in it
Rear panel as seen in the photo
The floorpan is also going where it meets the heelboard (just in front of the tank)


You can probably also notice that the firewall has been cut out and the battery tray has been cut and reinforced for a Corsa pedal and MC conversion

good stuff, look forward to progress
needs moving to projects tho lol

http://i669.photobucket.com/albums/v.../InnerWing.jpg


Both inner wings are still in good condition with no work required. Need to get the black underseal stripped off the arches though to check nothing nasty is hiding underneath. I took my wing off and started sanding it down with my new orbital sander I got the other day. Also started the petrol tank and had a bit of spraying practice because I'm hoping to do as much of the bodywork myself as I can

http://i669.photobucket.com/albums/v...andingWing.jpg

Found a couple of small holes along the bottom but will probably fill these rather than trying to source another wing, plus I'm not trying to create a concourse show winner lol

http://i669.photobucket.com/albums/v...andingTank.jpg

Just had a bit of practice priming part of the tank. I may look into sourcing a better condition tank as you can see the rust is quite severe at the right hand end on both sides of the tank :(

Cheers Spudly :thumb:

Hi,

Not had a good look at the Blue book lately but I thought you weren't allowed to modify the bulkhead - is cutting a hole for the corsa set up not modifying the bulkhead ?
Also the bias box, what is the issue with that ?
I know brakes cannot be adjusted from the drivers seat but that's not to say a bias box cannot be fitted without the dash adjuster. my interpretation maybe wrong.
Are you running in road car class or modified ?
Good luck with the build, I'll keep a look out for progress.

Im focusing more towards the road rallying, i need to have another read up on the regulations for hillclimbs as they are quite a bit stricter in terms of modifications to the body and the removal of trim. I know that a heater will have to go back in to satisfy the modified production car class

http://i669.photobucket.com/albums/v...ersAndDash.jpg

Most of the parts have been stripped off the car so that i can concentrate on the bodywork but unfortunately i have nowhere else at the minute to store bigger bits like the seats, radiator, dash and bumpers :( which is putting a bit of a hold on the project

http://i669.photobucket.com/albums/v...teriorMess.jpg

Removed the complete wiring loom and now stripped all the unnecessary wiring and labelled everything up ready to go back in. The main cable from the battery needs re-routing though as the battery will be relocated to the boot and will sit on a Corsa battery tray which will be welded in. This is about as far as I have got so far except for the work on the internal shifter

http://i669.photobucket.com/albums/v.../Teardrops.jpg

Matt_Vaughan brought me 6 GTE teardrop alloys over last weekend in a cash swap for a homemade bike carb manifold. A lot of people dont like these wheels but I'm a big fan of them - i now have 10 of them!!! lol

Which means i have two full sets of 5 wheels which can be fitted with different tyres for different surface types. Going to have a go at prepping and painting some of them in next couple of weeks. What colours to go for?!

That's a first for me......I can't recall ever having seen a wood-effect steering wheel on a Nova before!

im loving the plans il be watching this.

it was already in my previous Nova along with the 6 bolt boss which was obviously worth keeping lol but the wheel will be binned in favour of sumat decent, just kept it to keep the shell moveable

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Originally Posted by mk1nova_rich

it was already in my previous Nova along with the 6 bolt boss which was obviously worth keeping lol but the wheel will be binned in favour of sumat decent, just kept it to keep the shell moveable

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glad to hear that matey lol

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Originally Posted by novarally

That's a first for me......I can't recall ever having seen a wood-effect steering wheel on a Nova before!

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Especially not with a tight-corner-knob for grandad on it lol

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Originally Posted by MK999

Especially not with a tight-corner-knob for grandad on it lol

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Spaz knob lol i used it for an autotest last year!!

Thought i would post a brief spec of what im aiming for:

Stitch-welded shell with welded in rear brace
6 point bolt in cage
Sparco buckets and harnesses
Rear seats and door trim retained as per regs
Heated front screen
Polycarbonate windows (if permitted)
Battery moved to boot
Digital trip meter
Fire extinguisher (plumbed in kit if funds allow)
Quick rack

Gaz suspension kit (Golds depending on funds) and eccentric top mounts
Polybushed throughout
GTE tie bars and plated TCAs
Two rear ARBs (Nova + Mk2 Astra)

Corsa pedal and M/C conversion
Brake and fuel lines run through car with braided flexis
Hydraulic handbrake and bias valve
2.0 front brakes

F10 close ratio box with 4.18/4.53 FD
Competition mounts
Internal shift direct to box

1400 8 valve (full spec to be decided)
Facet 12v fuel pump
Sportex competition system

This is all i can think of for now but will add to list if i think of anything :thumb:

How are you managing to fit the Mk2 Astra Anti-roll bar Rich?

sounds like a good spec mate, good luck

be nice to see motor spec:D

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Originally Posted by matt_vaughan

How are you managing to fit the Mk2 Astra Anti-roll bar Rich?

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I'm sure its the Mk2 Astra one that can be fitted underneath the beam if you weld a few brackets onto the beam...maybe a Cav one im thinking of, will need to investigate.

Off to do a bit more clearing out on that garage in Brighouse at the weekend, can't wait to get the shell moved in there for the winter :cool: least i will be able to get stuff done somewhere dry and fairly warm. Will try and get some pictures of it while i am there.

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Originally Posted by philip

be nice to see motor spec:D

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Well im thinking of boring a 1300 out to take 12ST pistons to make a nice high compression 1396cc, then if necessary machine the pistons so that the CR is somewhere in the region of 10.5 - 11:1. Don't want to take it too high as i want the engine to be a nice compromise between performance and reliability/durability.

Then this is a rough sort of spec of what I'm going for:

Bottom end lighten and balance
Lightweight steel flywheel
ARPs
New oil and water pumps
New bearings/gaskets/bolts etc
Worked head
4 branch OR worked SR manifold and downpipe
Mk1 Astra inlet
Weber 34/32 carb
Cam to be decided

Your input and advice would be great :thumb:

Rich, you thought about using an 1.4/1.6 MPi head to bring compression down a bit? Cheaper and would also benefit from larger valves. Not sure how it would go down with regulations mind.

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Originally Posted by matt_vaughan

Rich, you thought about using an 1.4/1.6 MPi head to bring compression down a bit? Cheaper and would also benefit from larger valves. Not sure how it would go down with regulations mind.

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i think that may take the CR down too much Matt, and also brings issues of different port shapes and getting manifolds to suit. I don't think scrutineers pick up on stuff like that lol its probably permitted anyway... even if its not the hybrid 1400 wouldnt be either!

As some of you may have seen i started an internal shift conversion but bypassing the Nova linkage and running direct to the gearbox with a custom linkage and lever. If not here is the thread for the first part of it

http://www.pngclub.com/forum/showthr...=153889&page=7

I will then carry on details and pictures of this in this build thread :thumb:

http://i669.photobucket.com/albums/v...HoleOpened.jpg

I opened up the hole i had drilled in the bulkhead for the linkage to pass through, I had run out of jigsaw blades so did it pikey-style with a grinder and cutting disc lol this was done to try and straighten up the route of the shifter rod from the lever to the gearbox. I was also looking at clearance under the linkage as it is now and i think that i will be able to move it down around 15mm from where it is now to still clear the steering rack.

I get paid tomorrow so I am going to order the spherical bearings for the shifter box and bulkhead and also some alloy tube for the actual shifter rod. Decided on 20mm O/D which should be sturdy enough for the job and i will have no trouble getting the bearings for this size.

Polycarbs are aloud in road rallying regs although your nav will hate you as will make his job harder! I fitted electric window for nav as we get through controls alot quicker without him messing about

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Originally Posted by SR-Rally

Polycarbs are aloud in road rallying regs although your nav will hate you as will make his job harder! I fitted electric window for nav as we get through controls alot quicker without him messing about

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Yeh just need to check about which class i would be in for hillclimbs and whether they are permitted for that. May just leave standard windows in for now and fit polycarbs when the car is up and running. Are you allowed to open the door at controls or not?

yeah you can open the door just will loose few seconds as time it takes your nav plus all marshalls go straight to window and get in way of opening door lol

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Originally Posted by mk1nova_rich

I'm sure its the Mk2 Astra one that can be fitted underneath the beam if you weld a few brackets onto the beam...maybe a Cav one im thinking of, will need to investigate.

Off to do a bit more clearing out on that garage in Brighouse at the weekend, can't wait to get the shell moved in there for the winter :cool: least i will be able to get stuff done somewhere dry and fairly warm. Will try and get some pictures of it while i am there.

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its a mk2 asrta gte one mate, ive had this done om my gsi, when i get the rear beam of ill get pics for you

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Originally Posted by bazil

its a mk2 asrta gte one mate, ive had this done om my gsi, when i get the rear beam of ill get pics for you

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cheers pal, that would be great :thumb:

Right, no real updates as i have been busy with work and weather has been truly crapwhen I have been free but my latest purchase has been a reconditioned steering rack with 2.1 lock to lock internals... how much harder are quick racks to turn than a standard rack, as I may have to look into fitting EPAS?!?

Also been wire-brushing my front outer wings and I think another pair will need sourcing as they are quite crusty underneath the paint close to the rear edges. Bit of a bugger really as I thought they looked ok :(

Hey dude, thanks for the good seller rep :thumb:

Just had a ganders through your project thread.
With regards to whether you need EPAS, I should fit the rack and try it out before you go to the bother of fitting an EPAS column. As long as you don't fit a tiny steering wheel I reckon it won't be so bad once you're going faster than car park speeds + I assume this project won't end up in use as a daily driver?
+ an EPAS unit is quite a heavy a lump to add in.
To keep weight down, as well as polycarbs...
(should save a good few kg's as standard glass all round is heavy stuff)
...are you aloud to de-iron the bumpers.
I've done it, really easy to do, takes a hour or so, all you need is a drill and a couple of pairs of bonnet clips (to do front and back) and when you strip the irons out you save a lot of weight + quick release bumpers :d

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Originally Posted by Jakey Boy

Hey dude, thanks for the good seller rep :thumb:

Just had a ganders through your project thread.
With regards to whether you need EPAS, I should fit the rack and try it out before you go to the bother of fitting an EPAS column. As long as you don't fit a tiny steering wheel I reckon it won't be so bad once you're going faster than car park speeds + I assume this project won't end up in use as a daily driver?
+ an EPAS unit is quite a heavy a lump to add in.
To keep weight down, as well as polycarbs...
(should save a good few kg's as standard glass all round is heavy stuff)
...are you aloud to de-iron the bumpers.
I've done it, really easy to do, takes a hour or so, all you need is a drill and a couple of pairs of bonnet clips (to do front and back) and when you strip the irons out you save a lot of weight + quick release bumpers :d

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Cheers for the input mate, i have been considering fitting the Corsa EPAS for a while but the extra weight and space issues under a Mk1 dash have been swaying me towards not bothering with it. Plus the car will not be used as a daily driver so there are no issues with parking difficulty and so on.

I have already de-ironed the bumpers and fitted quick release pins :p just you can't see because the bumpers are off.

good luck with the build matey !!
:thumb:

Cheers pal, not really done much with it for over a week now :( but went down to my new storage last weekend to clean it out, couple more days down there and it should be ready for the Nova to go in over the winter - its attracting too much unwanted attention sat on the drive. Someone i know has a garage under their house which they dont use, so have let me use it long term free rent :d only downside is having to clean it out which was like sumat of Grimebusters lol getting there now though just need to get rid of a fridge and an old sofa and then im going to pressure wash the floor of it. Pics of the garage will be up when its fully cleaned :thumb:

[quote= Someone i know has a garage under their house which they dont use, so have let me use it long term free rent :d [/quote]

carnt beat that then matey, atleast it will be under cover from the cold
:thumb:

yep, especially as the boiler is at one side and the hot water pipes run through it :d the roof is a bit low (around 6'5") and the doorway even lower but not gona get anything better without paying for it

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Originally Posted by mk1nova_rich

yep, especially as the boiler is at one side and the hot water pipes run through it :d the roof is a bit low (around 6'5") and the doorway even lower but not gona get anything better without paying for it

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:thumb:

want to get it down there by end of October so i can really crack on with bodywork, especially tackling the crusty bits before they get worse and then prepping the shell for a respray :) gona be brilliant having somewhere warm and dry to work in over winter

Quote:

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Originally Posted by mk1nova_rich

want to get it down there by end of October so i can really crack on with bodywork, especially tackling the crusty bits before they get worse and then prepping the shell for a respray :) gona be brilliant having somewhere warm and dry to work in over winter

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ye i dont like working in cold conditions , i need to start saving money to be spent on Sr, just havent got the funds to start yet and gotta get collecting bits for it but will get there in the end :thumb: