My Nova Build -WIP-

Had the spacers for the coilovers cut and matched for size on a lathe.

Heres a pic of the gap I needed to fill when the coilovers were bolted to the topmounts
http://img.photobucket.com/albums/v3...a/DSCN2354.jpg

And here with the spacer in place all tight with no play
http://img.photobucket.com/albums/v3...a/DSCN2356.jpg

Front Coilovers built up
http://img.photobucket.com/albums/v3...DSCN2357-1.jpg

Hubs cleaned up and painted
http://img.photobucket.com/albums/v3...a/DSCN2350.jpg

Fitted some sparco pedals that I got for £2 from VBOA a couple of years back!!
http://img.photobucket.com/albums/v3...a/DSCN2352.jpg

Got the coilovers bolted to the hubs and the bottom arm arrangement all in place. Looks proper fresh if I do say so myself!! :)
http://img.photobucket.com/albums/v3...a/DSCN2361.jpg

http://img.photobucket.com/albums/v3...a/DSCN2359.jpg

http://img.photobucket.com/albums/v3...a/DSCN2360.jpg

Then tried the discs on
http://img.photobucket.com/albums/v3...a/DSCN2363.jpg

When I tightend the discs to the hubs I found that they were catching on the back of the hub, I have some spiggot rings for the v6 brake conversion. Do these go behind the disc to space it out?? Anyone else had any trouble with the discs catching on the hub with the v6 brakes??

Any help or info will be greatly appreciated :D

I've decided on running the topmounts the correct way up as I can't really gain any (if not very minimal) castor on the standard bottom arm setup, and only need to get -2 camber so just mounted them as far back as I could get them... If I do need a little more I will turn down the top a little on a lathe.

http://img.photobucket.com/albums/v3...a/DSCN2365.jpg

http://img.photobucket.com/albums/v3...a/DSCN2366.jpg

Quote:

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Originally Posted by AW06

Where you get the new TCA bolts from? I need one lol

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Just a local tool and engineering shop. Took in the old one and asked for something similar. They haven't got the washers built into the nut or bolt, but not an issue

Wow good progress man. Like the black on white.

Aye i thought so. I need to get a couple for mine since i lost them lol :roll:

Nice one, susp goodies are looking very nice.

They look like the same topmounts as mine, and according to the fancy machines mine is running around 1deg neg camber and 1deg pos caster in the far back and slightly in position. Should be able to sacrifice some caster for more camber though.

Keep up the good work.

Looking great Ian, nice new shiny bits :)

Spigot rings only centre the disc, they dont space it out.

Dont suppose you have any more of that spacer tube do you? I think that gap might be the cause of a bit of play in my avo's, making a light knock sound at slow speeds.

How did you manage to tighten up the top mount spacer nut? (seeing as it covers the flat on the damper piston), hence why i ended up drilling it out and using the normal avo nuts/

Looking really nice, nice feeling bolting fresh bits on to a shell.:thumb:

Keep going mate, will be running next weekend ;)

is this not done yet lol

Love the shock build but.

Quote:

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Originally Posted by Adam

Looking great Ian, nice new shiny bits :)

Spigot rings only centre the disc, they dont space it out.

Dont suppose you have any more of that spacer tube do you? I think that gap might be the cause of a bit of play in my avo's, making a light knock sound at slow speeds.

How did you manage to tighten up the top mount spacer nut? (seeing as it covers the flat on the damper piston), hence why i ended up drilling it out and using the normal avo nuts/

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Cheer's Adam. I do have two pieces of that spacer tube left, but there both different lengths!! You will have to have them turned down on a lathe to make sure both edges are 100% flat and as its mega hard steel, we couldn't cut through with a hacksaw!

As for the top nut on the coilovers for now I just got it as tight as I could. It will be redone so it goes further down at a later date. just used it for now to get it on its wheels.

The Disc on the drivers side hub is causing a massive problem though! I thought maybe it wasn't seated properly as it only caught in one place in a full revolution, but had a look today and tightened it on and its still catching. Compared to the one on the passenger side that has about 4mm clearence. Dont know what to do about it because, if I were to space the disc out the calliper wouldn't fit right. I'm wondering if its a problem with the hub??

..... And thanks everyone else for the comments. It sure does feel good bolting new bits on but seriously annoying getting all these niggles and problems!!

Got some more done today. was going to bolt the pedal box in, but on closer inspection of the bulk head area there was not alot of paint on it, so got gave it a lashing with a rattle can. So didn't get the pedals in after all as I had to let that dry off! lol

Although I got the Boot pins on
http://img.photobucket.com/albums/v3...a/DSCN2372.jpg

Rear lights on, and polycarb rear screen in
http://img.photobucket.com/albums/v3...a/DSCN2369.jpg

And side polycarbs in too, with GSI surrounds painted satin black
http://img.photobucket.com/albums/v3...a/DSCN2370.jpg

And Steve wrapped my whole wiring loom in non adhesive loom tape :thumb: Cheers matey. Also scraped off some the reacted stone chip on the front pannel and re painted it. Still looks a mess to be honest, but a better mess! lol Will probably re do it again, but its not an important job at the mo

Are your bearings pressed in correctly?

Nice to see what youve got on with Ian.
Keep up the good work mate.

As far as I know, I got the hubs already built up so can only assume they are. But the fact the disc is to far in would suggest that the bearing would be pressed in too far, and then the circlip wouldn't have gone in?? Will have to have a closer look, but when I was looking at both hubs when I painted them there was no obvious differences

Edited - Thanks Chris!! Just saw your post as I posted this!!

Quote:

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Originally Posted by t45_ste

Are your bearings pressed in correctly?

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Do Nova's use tapered bearings on the front or a roller typre bearing?, either way i cannot see this happening. Because on a roller type bearing you can only press it so far into the hub then you have a circlip, and there is know way of getting the circlip in without the bearing being pressed in to the hub all the way.

Im 99% sure there a roller type bearing anyway.

Jay.

Few more bits done this weekend...

Saturday morning I dropped my bottom end off at Autosprint for balancing and flywheel lightening and balancing, that should hopefully be ready for next weekend :cool:

Todays work included laying the wiring loom roughly in place after having it all nicely wrapped in non adhesive loom tape.

Pedals primed, painted and in
http://img.photobucket.com/albums/v3...a/DSCN2375.jpg

Bias box in to hold pedal's in
http://img.photobucket.com/albums/v3...a/DSCN2384.jpg

http://img.photobucket.com/albums/v3...a/DSCN2386.jpg

Gearlever in, (although will have to come out again to modify the shaft)
http://img.photobucket.com/albums/v3...a/DSCN2376.jpg

http://img.photobucket.com/albums/v3...a/DSCN2383.jpg

Passenger seat and harness's mounted
http://img.photobucket.com/albums/v3...a/DSCN2380.jpg

http://img.photobucket.com/albums/v3...a/DSCN2378.jpg

http://img.photobucket.com/albums/v3...a/DSCN2377.jpg
Just need some small nuts and bolts to hold the spreader plates in place.

http://img.photobucket.com/albums/v3...a/DSCN2382.jpg

Then steve found a spider in a corner that got the 2 pak treatment when the car was painted lol
http://img.photobucket.com/albums/v3...a/DSCN2387.jpg

Finally back to the problem I'm having with the brake discs hitting the hub carrier we had a look at them again. The Disc that seemed ok on the passenger side wasn't catching as the bearing has alot of play in it. The hub carrier looks as though its been machined out too big so the bearing fit is to loose.

What front wheel bearings do people run for the 2ltr hubs?? I'm going to have my other hub carriers machined for the bearing so I know its all sorted and see if this resolves the catching issue

Its all coming along nicely bud - I bet you keep stopping just to stand back and admire it! lol

Looking good Ian, which is more than i can say for the spider, poor bastid :( lol

looking good Ian but i thought you would of finished this by now lol.
Keep up the good work mate.

Quote:

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Originally Posted by Ernie

looking good Ian but i thought you would of finished this by now lol.
Keep up the good work mate.

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Don't you start aswell lol

Thanks for the comments guys :thumb:

Any gen on what wheel bearings for the 2ltr hubs??

Bit more done tonight. Sorted out the issue with the brake disc catching on the hub carrier steering arm. There was alot of play in the the hub and we thought this maybe partly at fault as the disc may not have been sitting true, but after stripping it all down and having a look it was clear everything was ok as when the driveshaft was tightened up it took out all the play.

So we decided that the best solution was to grind a bit of the hub carrier as theres plenty of metal there and we only took off about 1mm. (Other idea was to space the disc out but this would have been a nightmare when fitting the calliper). So now there nice and free.

The problem area after being ground down, loads of clearance now!
http://img.photobucket.com/albums/v3...Image050-1.jpg

This shows where steering arm has been shaved
http://img.photobucket.com/albums/v3...Image052-1.jpg

Calliper spacer and carrier on
http://img.photobucket.com/albums/v3...Image048-1.jpg

And finally I had problems fitting my seat onto the standard subframe that had been modified for fitting fixed buckets, as the previous owner must have had wider seats than mine so there was a huge gap. So the mounts were cut off and rewelded to suit my seat and then painted up all nice

http://img.photobucket.com/albums/v3...Image053-1.jpg

http://img.photobucket.com/albums/v3...Image056-1.jpg

Thats ready to be bolted into the car now and I can finish mounting the drivers side harnesses.

Also decided to have my topmounts turned down so as I can get more camber (and castor eventually) so should get them back this week and it can all go together and go back on its wheels and then its on with the rear beam!!

I thought you had finished this and had started breaking it because you were board....lol

I did, this the next one :p lol

What breaks are you fitting then? (sorry if you have said, I'm lazy) lol

Its the 284mm V6 setup, but thats why I find it strange the problems I've had as not heard of anyone else having similar issues with this setup :confused: Strange!!

Sorted now anyway, I hope!! lol

284mm are turbo stuff, not v6.

Quote:

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Originally Posted by nova ian

Its the 284mm V6 setup, but thats why I find it strange the problems I've had as not heard of anyone else having similar issues with this setup :confused: Strange!!

Sorted now anyway, I hope!! lol

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Are you sure? V6 / turbo stuff bolts straight on without a spacer plate?? Fits same as 2ltr stuff

Mine bolted right on.

What discs are those?

Not a clue! I bought the seup off a friend as the V6 setup :confused:

Must be something different then! The callipers are identical to the 256 setup I had previously and as for discs I really don't know! they measure 284mm but will check again. But looking at it the calliper wouldn't go on without the spacer

Id put money on them discs not being vauxhall ones, so the offset on them is wrong, hence they sit too far "back" on the hub..... touching the knuckle

Yea that could well be the case, you have a PM ;)

looks like you've got a kit that goes bigger disc but respaces the 2ltr caliper.

tbh bud I'd either swap the setup for turbo or v6 or go 4 pots. V6 calipers are dead easy to come by as they were fitted to all 2ltr veccy's aswell. I may even have a spare pair in the shed if you can't find any local. Turbo ones would be better tho as they are meant to give a better pedal feel as they have a smaller piston.

Quote:

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Originally Posted by The Simps

looks like you've got a kit that goes bigger disc but respaces the 2ltr caliper.

tbh bud I'd either swap the setup for turbo or v6 or go 4 pots. V6 calipers are dead easy to come by as they were fitted to all 2ltr veccy's aswell. I may even have a spare pair in the shed if you can't find any local. Turbo ones would be better tho as they are meant to give a better pedal feel as they have a smaller piston.

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Cheers dude,

To be honest the only reason I bought this setup is that I got it so cheap with brand spanking new callipers. So seeing as I've got it sorted now i'm going to run this setup until I can afford a 4 pot setup later down the line.

I think it should still be adequate with the pedal box and full braided lines.

Few more bits done, not alot of pics....

I've had my Topmounts machined down by 3.5mm to get a bit more camber
http://img.photobucket.com/albums/v3...Image050-2.jpg

Couple of pics of the bottom end in progress
http://img.photobucket.com/albums/v3...a/Image051.jpg

http://img.photobucket.com/albums/v3...Image052-2.jpg

Balanced bottom end with ARP rod bolts. Now has sump on, cambelt backplate and pulleys. Then started on matching the inlet manifold and head ports. Didn't get any pics though, sorry :(

Drivers seats in and harness's all sorted
Left the harness's out though as the seats come back out for easier access!
http://img.photobucket.com/albums/v3...a/DSCN2392.jpg

Passenger foot rest in too
http://img.photobucket.com/albums/v3...a/DSCN2393.jpg

Internal brake line route into cabin
Need to get a grommet for the hole too
http://img.photobucket.com/albums/v3...a/DSCN2390.jpg

Handbrake in place
http://img.photobucket.com/albums/v3...a/DSCN2394.jpg

good work! soon be done.

Ive just read the from start to finsh, All i will say is this is a five star thread !