Iain's 20XE Trackday Nova

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04-09-09, 06:40 PM
Iain

I've finished removing the pistons if that's what you mean lol

http://iainel.co.uk/images/forums/NovaWIP2/542.JPG

A slight lip on a few of them actually, not massive but I don't really know what's big in engine terms:

http://iainel.co.uk/images/forums/NovaWIP2/543.JPG

Bore shows crosshatching marks:

http://iainel.co.uk/images/forums/NovaWIP2/544.JPG

Tried to finish removing the head studs and this is what the head stud extractor that "doesn't damage the thread so they can be reused" did to them lol Welded a nut to the end of them to get them out :roll:

http://iainel.co.uk/images/forums/NovaWIP2/545.JPG
04-09-09, 07:22 PM
Paul

Iain, did you grind a V into the join in the pedal, I would have done and filled that with weld.
04-09-09, 07:54 PM
Iain

I did not, there was a slight gap a bit like a V join would have been on one side though?

I've only just got over the worry of the pedal, good job lol I'll be plating it on one side tomorrow now!
04-09-09, 07:58 PM
Iain

I now have some badass flare on my front R/H wing to match the rear arch. Hooray.

http://iainel.co.uk/images/forums/NovaWIP2/546.JPG

http://iainel.co.uk/images/forums/NovaWIP2/547.JPG

http://iainel.co.uk/images/forums/NovaWIP2/548.JPG

http://iainel.co.uk/images/forums/NovaWIP2/549.JPG
04-09-09, 08:06 PM
Prey

Ur a very busy bugger.... looking quality tho mate!
08-09-09, 06:00 PM
Iain

Today's update, been doing bodywork which for a novice is very time consuming! Getting there though.

Arches almost done! Subtle flare on the front:

http://iainel.co.uk/images/forums/NovaWIP2/550.JPG

And rear one is taking shape, I find the biggest problem is getting where it starts to flick out look right as the light catches it slightly differently and highlights it:

http://iainel.co.uk/images/forums/NovaWIP2/551.JPG

http://iainel.co.uk/images/forums/NovaWIP2/552.JPG

Shifter plate smoothed in to the tunnel, looks almost factory:

http://iainel.co.uk/images/forums/NovaWIP2/553.JPG

Back almost done, with smoothed seatbelt holes:

http://iainel.co.uk/images/forums/NovaWIP2/554.JPG

Tinkering with my Aerocatches, they're currently like this:

http://iainel.co.uk/images/forums/NovaWIP2/555.JPG

I'd quite like to fit them like this, but the shape of the slam panel doesn't really allow for it. So I guess they'll stay as above!

http://iainel.co.uk/images/forums/NovaWIP2/556.JPG

A few parts bought. Quaife ATB diff:

http://iainel.co.uk/images/forums/NovaWIP2/557.JPG

New poly bushes as most of mine met a melty end with the welding work lol:

http://iainel.co.uk/images/forums/NovaWIP2/558.JPG

Weeny Racetech mirror weighing hardly anything:

http://iainel.co.uk/images/forums/NovaWIP2/559.JPG
08-09-09, 06:01 PM
stevie-p

looks ace love the arches - good work and progress
08-09-09, 06:03 PM
Adam

Arches are looking really good now.

And i need a parcel like that on my doorstep!!!! lol lol
08-09-09, 06:08 PM
peester

nice parts.. itll be a totally different animal
08-09-09, 06:35 PM
scott.parker

Good going mate, the cars going to be a nice drive once it's all back together, totally different car infact.
08-09-09, 09:14 PM
Benn

Looking good dude, catchs look good, like mean eye brows.

Get new manifold studs and nuts. Vx can do you a full set of about a tenner iirc.
08-09-09, 11:27 PM
021-bennettt

I just went through all of the pages and my eyes are hanging out of my head...was nearly too tired to write this comment lol EXCELLENT work!
08-09-09, 11:48 PM
burgo

loving it all
09-09-09, 05:21 PM
Iain

Thanks all for your kind comments.

Quote:

Originally Posted by Benn

Get new manifold studs and nuts. Vx can do you a full set of about a tenner iirc.

Yeah was planning on doing, a tenner doesn't sound bad. :)
09-09-09, 05:24 PM
Paul

Nice Iain, the quaife is the best thing you can do to a big block.

Its a shame that you wont have driven an XE without one, so you can see just exactly how good it is!
09-09-09, 05:31 PM
Iain

I'll drive Adams when I'm back on the road with drive-other-cars, assuming he hasn't bought one before mine's finished!
09-09-09, 05:53 PM
scott.parker

Quote:

Originally Posted by Paul

Nice Iain, the quaife is the best thing you can do to a big block.

Its a shame that you wont have driven an XE without one, so you can see just exactly how good it is!

I finally got to test mine at combe, MASSIVE improvement! :thumb:
10-09-09, 11:05 AM
Mazz

Where did you buy your diff from Iain?
10-09-09, 01:02 PM
Iain

All the latest parts are from RallyDesign.
11-09-09, 05:21 PM
novalovingned

Good progress. I might actually get to a show next year to see this in the metal. Providing its finished :)
11-09-09, 05:23 PM
draper

Quote:

Originally Posted by novalovingned

Good progress. I might actually get to a show next year to see this in the metal. Providing its finished :)

lol

nice shiny bits lionel

did you have a look at that astra ?
12-09-09, 06:31 PM
Iain

Couldn't find the Astra, looking at Volvos at the moment lol

Yep it'll be at the shows next year, in the metal and filler lol

Smoothed off the plates in the engine bay to try and achieve a more factory look. Before (plating them seems like ages ago now!):

http://iainel.co.uk/images/forums/NovaWIP2/088.JPG

http://iainel.co.uk/images/forums/NovaWIP2/099.JPG

After:

http://iainel.co.uk/images/forums/NovaWIP2/560.JPG

http://iainel.co.uk/images/forums/NovaWIP2/561.JPG

More work on the rear arches, using more filler than I'd like to but they should look good when finished:

http://iainel.co.uk/images/forums/NovaWIP2/562.JPG

http://iainel.co.uk/images/forums/NovaWIP2/563.JPG

Smoothed boot floor (factory spot weld marks and unevenness from chassis leg stitching);

http://iainel.co.uk/images/forums/NovaWIP2/564.JPG

http://iainel.co.uk/images/forums/NovaWIP2/565.JPG

More on the exhaust tunnel to get that looking decent:

http://iainel.co.uk/images/forums/NovaWIP2/566.JPG
12-09-09, 06:35 PM
Adam

This is loooking too good for my liking
12-09-09, 06:35 PM
The Simps

I really hope it doesn't all crack first trackday you do :(

Good work as always bud.
12-09-09, 06:36 PM
Jay

:)
12-09-09, 06:36 PM
Ste L

nice Iain, looking lovely and smooth
12-09-09, 06:38 PM
Iain

Quote:

Originally Posted by The Simps

I really hope it doesn't all crack first trackday you do :(

Good work as always bud.

lol Me too. I used a special flexible filler for the engine bay so hopefully should overcome any cracking possibilities.
12-09-09, 06:39 PM
Adam

Quote:

Originally Posted by The Simps

I really hope it doesn't all crack first trackday you do :(

Good work as always bud.

With the amount of weldage hes put into this thing i cant see that happening lol
13-09-09, 01:27 AM
novalovingned

Quote:

Originally Posted by Adam

With the amount of weldage hes put into this thing i cant see that happening lol

+1

I would feel sorry for anything he hits.
13-09-09, 03:42 AM
draper

fancy coming and doing the filler work on my 106 lionel ?
13-09-09, 08:49 AM
Adam

Hes already told me hes had enough of bodywork once his cars done lol lol
Wanted him do my arches lol
13-09-09, 09:59 AM
Benn

Awesome work dude, good job on the bay, still looks factory ish.
13-09-09, 11:15 AM
Iain

Cheers all, it's not that much welding?! Yeah it'll hopefully look "normal" once it's finished and painted, and I've put seam sealer over it.

Why have I got a queue of people wanting my DIY bodging skills lol I'll no doubt get bored of not welding etc when my car's finished tho!
22-09-09, 05:44 PM
Iain

Feels like I've been slacking lately, been putting in lots of hours to try and finish the bodywork to a good standard. Think I've decided to hand it over to somebody to paint though, so might let them finish off the pillars etc.

Seam sealered most of my engine bay, including where I filled so it looks normal. Not a bad job, just need to buy some more to finish it off.

http://iainel.co.uk/images/forums/NovaWIP2/567.JPG

http://iainel.co.uk/images/forums/NovaWIP2/568.JPG

Won't look bad when it's painted:

http://iainel.co.uk/images/forums/NovaWIP2/569.JPG

Also got some GSi dials so I don't need to chop the wiring about for my digidash, as I dream of getting a Stack dash eventually lol Reset the mileage to 0 to track the mileage of the new engine!

http://iainel.co.uk/images/forums/NovaWIP2/570.JPG
22-09-09, 05:53 PM
scott.parker

Cool looks good mate, but whys that cardboard box producing Oil pressure!? :confused: mega fire hazard!:eek:

lol
22-09-09, 06:35 PM
Benn

Looks good dude!
27-09-09, 06:02 PM
Iain

Rest of the car has been seam sealered and reprimered now, I just need to paint the inside and engine bay and ship it off to a bodyshop.

http://iainel.co.uk/images/forums/NovaWIP2/571.JPG

http://iainel.co.uk/images/forums/NovaWIP2/572.JPG

http://iainel.co.uk/images/forums/NovaWIP2/573.JPG

http://iainel.co.uk/images/forums/NovaWIP2/574.JPG

http://iainel.co.uk/images/forums/NovaWIP2/575.JPG

http://iainel.co.uk/images/forums/NovaWIP2/576.JPG

http://iainel.co.uk/images/forums/NovaWIP2/577.JPG

Also trial fitted my fibreglass bonnet, fits well!

http://iainel.co.uk/images/forums/NovaWIP2/578.JPG

http://iainel.co.uk/images/forums/NovaWIP2/579.JPG
27-09-09, 06:04 PM
djbrowney

awsome progress not looked at the thread for a while, who you going to get it painted by ???
27-09-09, 06:08 PM
Iain

On with fitting the Aerocatches! Dreading this job on a new fibreglass bonnet but wasn't as bad as expected.

Pins fitted from previous installation here:

http://iainel.co.uk/images/forums/NovaWIP2/580.JPG

Cut away some of the inside to line it up and mark where to drill (red dot):

http://iainel.co.uk/images/forums/NovaWIP2/581.JPG

Hole on the surface of the bonnet is roughly 100mm in from the side and 125mm back from the front:

http://iainel.co.uk/images/forums/NovaWIP2/582.JPG

http://iainel.co.uk/images/forums/NovaWIP2/583.JPG

Lost the original template so mocked something up from my old bonnet and measurements off the web:

http://iainel.co.uk/images/forums/NovaWIP2/584.JPG

Drawn on, front edge lines up with the front edge of the bonnet:

http://iainel.co.uk/images/forums/NovaWIP2/585.JPG

http://iainel.co.uk/images/forums/NovaWIP2/586.JPG
27-09-09, 06:08 PM
Iain

Multi tool with cutting disc is my weapon of choice:

http://iainel.co.uk/images/forums/NovaWIP2/587.JPG

Cut:

http://iainel.co.uk/images/forums/NovaWIP2/588.JPG

Removed:

http://iainel.co.uk/images/forums/NovaWIP2/589.JPG

Next up, shaping it with this sanding thing on the multitool:

http://iainel.co.uk/images/forums/NovaWIP2/590.JPG

Perfec':

http://iainel.co.uk/images/forums/NovaWIP2/591.JPG

http://iainel.co.uk/images/forums/NovaWIP2/592.JPG

Shaped nicely around the back of the Aerocatch (downside is I won't be able to use 3 of the original bolts but some tigerseal should keep it in place:

http://iainel.co.uk/images/forums/NovaWIP2/593.JPG

Job's a goodun:

http://iainel.co.uk/images/forums/NovaWIP2/594.JPG

http://iainel.co.uk/images/forums/NovaWIP2/595.JPG

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