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Aye.
Theres nothing I'd like more than to do a crazy nut & bolt resto' but I feel like Ive come to my senses ever since I moved out of home & tbh I have almost no motivation to be spannering under my car. Those days seem to have gone, however I am having a hoot charging about the place in my 1.2 so I have no doubt I will enjoy this when I'm done building it.
Been home at lunchtime & my Corsa track rods were there courtesy of VPSC. :thumb:
looking good craig , glad you kept this one as it did look mint :thumb:
All looking good craig, should see this at the shows next year then :)
Good work matey! Keep it up, hope your finger nails are as full of crap as mine are at the mo lol
hows the corsa servo coming on mate?? like simps has said mate your work on your car is excactly how i wont mine keep up the good work and keep us posted!!:thumb:
Looks like a good build. Rear turrets look spot on. Good work fella.
Ian
Had a busy day off from work & have set about sorting the Corsa servo into its rightfull position, after much debating & research. Here goes.
Its going in the battery tray as previously written, here;
http://i30.photobucket.com/albums/c3...-Z_Nova015.jpg
With the battery removed from the battery tray area, it looks a little something like this;
http://i30.photobucket.com/albums/c3...s/STA40597.jpg
Here is said Corsa GSi servo & master cylindeder assembly;
http://i30.photobucket.com/albums/c3...nkservo004.jpg
Its mounted through a stiffening tray that has extra bolt in points than just the servo-to pedal bolts (x4).
http://i30.photobucket.com/albums/c3...nkservo005.jpg
First job was to rid the inside of the footwells of the old transfer bar & pedal assembly/litter
Out with the pedals...
http://i30.photobucket.com/albums/c3...s/STA40581.jpg
http://i30.photobucket.com/albums/c3...s/STA40586.jpg
To leave an empty bulkhead...
http://i30.photobucket.com/albums/c3...s/STA40584.jpg
Then set to with creating the 2nd support for the clutch pedal as the Nova brake pedal was the 2nd support bracket for the std clutch pedal. To do this me & mate Rob decided to space the existing brake pedal (now chopped down in length) closer to the clutch pedal & then rotate it 180 degrees so it now sits up at the top of the bulkhead/underside of the battery tray.
http://i30.photobucket.com/albums/c3...s/STA40600.jpg
We then welded to lengts of steel in a V formation to sit in the recess under the bulkhead by where the new support bracket could meet & be bolted down securely.
http://i30.photobucket.com/albums/c3...s/STA40601.jpg
Here is the support bracket bolted up independant of the clutch pedal (note wing nuts used for quick installation).
http://i30.photobucket.com/albums/c3...s/STA40602.jpg
This was then welded up solid & relevant sized holes drilled & then sprayed with primer.
Moving back out to the battery tray, we had the holes centre punched so we needed to bore the large hole to pass the plunger on the servo through which mounts up to the pedal in the car.
A few score lines & marker pen marks & we got this...
http://i30.photobucket.com/albums/c3...rogress002.jpg
http://i30.photobucket.com/albums/c3...rogress001.jpg
Which meant we could slot this in...
http://i30.photobucket.com/albums/c3...rogress003.jpg
Next step is to straighten the Corsa's pedal & then work out the position of the pedal pad as it will need to be shortened to bring it up inline with the clutch pedal next to it. We hacked off the bottom part & then used molegrips to adjust the position before welding it when happy with the result.
http://i30.photobucket.com/albums/c3...nkservo006.jpg
http://i30.photobucket.com/albums/c3...rogress007.jpg
http://i30.photobucket.com/albums/c3...rogress010.jpg
http://i30.photobucket.com/albums/c3...rogress008.jpg
That will be welded properly & painted up by tomorrow, so the next stage of swapping to the PAS rack & deciding where to put the 12v pump in will be next, as is ordering a bias valve (in-car adjustable) & making up the piping for the brake system.
Order the hoses, pipe, fluid, spigot rings, PAS plumbing & reservoir ?tc ?tc.
Ive also obviously had the steering column off, so I have been able to change the column bearing Ive been itching to do for a few years now..
http://i30.photobucket.com/albums/c3...s/STA40580.jpg
Its located under the upper column cowling, in the brown plastic bit in the centre, the old OE bearing was pretty ruff.
New bearing & old bearings.
http://i30.photobucket.com/albums/c3...s/STA40578.jpg
Thenew one is slotted in with some marine grease to keep it smooth, I put some grease on the lower plastic bush that the coloumn spins on too.
looking very nice!!! :thumb:
Word of warning, the nova bulkhead/firewall is very weak. I had to create a large metal wedge construction to brace the back of the pedal hinge bracket to the bulkhead. Its hard to describe, but when i pressed the pedal hard the battery tray would flex upwards like hell and attempt to seperate at the seam with bulkhead.
looking good craig!! keep us posted!! and i'l bear that in mind Oli!!
Lovely fella.
Thanks. Bit more progress...
PAS rack is now fitted (well hole drilled) anyway & the pipes are ordered up from PIRTEK.
http://i30.photobucket.com/albums/c3...rogress012.jpg
http://i30.photobucket.com/albums/c3...rogress013.jpg
Got these Samco's from an SR I broke last month, should be able to use a couple of them with a bit of luck.
http://i30.photobucket.com/albums/c3...rogress011.jpg
New Walbro fuel pump arrived today aswell (thanks JoeThrelk). Nice.
just gotta sort where I want to put the battery & the PAS pump, then I can calculate the lengths needed for the pipes.
Put the battery in the boot :thumb:.
Saturday 28th Oct 06. My mate Rob came round wiv BIGG Mikes crane. This is Rob hauling the engine out the garage whilst I hold the camera & keep my hands clean. As it happens I helped lift the engine out to here & had my fingers in the muckiest place possible, really gacky oil on my hands. (Not good for the camera) LOL http://i30.photobucket.com/albums/c3...rogress020.jpg
Here she is sittin under the raised front end in anticipation for the car to be lowered over the lump (sorry Benn, its the best way!). Consequently we only removed the wheels & tie bars for this today, easy with an impact gun.
http://i30.photobucket.com/albums/c3...rogress021.jpg
And here sitting pretty... in quite nice time, my TAS mounts arrived from Karl Rowntree this morning, thanks bud.
http://i30.photobucket.com/albums/c3...rogress025.jpg
http://i30.photobucket.com/albums/c3...rogress014.jpg
Here it is just hanging out in the shade..LOL
http://i30.photobucket.com/albums/c3...rogress022.jpg
Now the engines in out the way, my Dad will quit moaning & I'll have a much better idea as for where to put the 12v PAS pump & where to route the pipes, locate the reservoir & hide the battery.
Any suggestions, mainly for the PAS graetly accepted. By the way! Does anyone know the ins & outs of a Corsa GSi PAS rack & which union is pressure &/or return?
nicely done:thumb:
Heres my brake bias valve for the rear disc brakes..
http://i30.photobucket.com/albums/c3...rogress026.jpg
The BRAND new Walbro fuel pump I got for ?65..!!
http://i30.photobucket.com/albums/c3...rogress027.jpg
http://i30.photobucket.com/albums/c3...rogress028.jpg
Should be busy this week, Ive got plenty to be getting on with.. Slap me if I'm SLACK!
Hi mate, looks a great build, sorry to be a pain but could you give me abit of info on whats needed to fit Corsa PAS and also Turrting the rear
Cheers
looks good craig, im really likeing thise rear turrets aswell
The Corsa hydraulic PAS is using a Corsa B hydraulic rack (GSi) & then shorten the track rods 1". I will have to get custom pipes made to plumb it into the 12v electric pump Ive bought. The rack needs the hole into the cabin enlarged as the hydraulic rack is a bit bigger here.Quote:
Originally Posted by Stu16vT
The turrets are hard welded into the rear chassis legs & boot floor/inner wheel arches so that the coilovers can take the full weight of the rear of the car & then the inner arches wont have to be dressed with a hammer to clear the coilover bodies. (std body shells with coilovers @ the rear can pop the inner arches apart). My shell was really rusty at the chassis legs, so I chose this expensive option to do away with rear springs, which essentially means the chassis leg/spring cup isnt structural anymore.
My Dad made the turrets or you can buy off the shelf mk2 Escort (rwd) ones from rally accessory suppliers.
The old servo mount is quite handy for running the loom into the cabin. Grommet fits a treat too.
http://i30.photobucket.com/albums/c3...rogress025.jpg
I think I'm going to mount the battery here via a welded tray bolted to the servo bracket. Should look factory & then I wont sacrifice volts or boot space by having it in the boot, not to mention a kilo of positive cable!
Looking good craig, love it :)
Keith
Could the PAS tank go where the washer bottle tank goes then get a washer bottle from a scrappy and have it in the wheel arch?
Simps.
p.s I do hope that engine will be coming out again to be cleaned and painted up ;)
In a word NO. been there & done that, it doesnt last & makes me want to cry when it gets dirty, the engine has a clean (20k) bottom end anyway & I will have the rocker cover polished & buffed again I expect + I will paint the g/box. Should have done it before I installed it but couldnt be harassed.Quote:
Originally Posted by The Simps
I think I will move the washer bottle into the scuttle tray & try to mount the PAS pump below the battery which should with a bit of luck all fit in the void above the gearbox/OE servo position.
il get you a pic of my tray in that place so ya can see what it looks likeQuote:
Originally Posted by craig green
phil
Ah nice one! Great minds think alike.
*SLAP* lol, any updates? or has it been put away for the winter? Should be able to pick that CS15 head (if you still have it) up in about a month when im back home with transport. very good project btw:thumb:Quote:
Originally Posted by craig green
A
Very slack here..
Head is sold buddy. Went to a mate of mine with a 1.6 8v turbo!!
:cry: oh well, if only i had the cash at the time. At least its beening put to good use.
A
Yeah. Soz about that, needed it gone for some time & let it go to Luke, he had the cash.
OK. Dunno where the motivation came from but Ive just returned from the garage.
After all the rain & shizzle we've had here in Somerset recently, the hole I bored in the battery tray was letting water into the cabin & suffice to say the drivers footwell was a bit damp. So I want the servo bolted down once & for all. I had to remove the rear battery rest, which left behind a bunch of holes from the spot welds. Anyone that knows about Novas will be aware that the battery tray is above the drivers feet. Any holes here will give you damp jeans & probably a wet fuse box, FORD Orion stylee.
http://i30.photobucket.com/albums/c3...rogress031.jpg
So spot weld holes sealed up with some seam sealer..
http://i30.photobucket.com/albums/c3...rogress033.jpg
And Ive also had some slight surface rust from where the battery has moved in the past & rubbed the paint. This has been on the car since I had it 8 yrs ago. Its never got worse or bothered me, but rust does have a habit of eating through metal & making holes, so again for the sake of dry jeans & sound electrics Ive rubbed it back & etch primed it.
http://i30.photobucket.com/albums/c3...rogress034.jpg
Tonights work in its entirety. LOL
http://i30.photobucket.com/albums/c3...rogress036.jpg
Little tip for 2007. Judging by all the Nova builds, invest heavily in this stuff. Guaranteed return!
http://i30.photobucket.com/albums/c3...rogress032.jpg
Tomorrow I'm going to bolt in the servo, pedal & mounting plate with the sealer ring so its water tight.
Then brake lines, something Ive been stalling on.
OK. Been under the fooker again this weekend. I need it to steer so I can move the car about & begin some work at the rear end (tank etc).
I had to remove the old std manual steering rack. here undoing the rack mounts from under the car (drivers arch)
http://i30.photobucket.com/albums/c3...rogress047.jpg
With the rack off I measured accross the centres of the 'rod ends' so I could set up the PAS rack to the same width just as a reference & to make tracking it up quicker when she's a goer.
http://i30.photobucket.com/albums/c3...rogress049.jpg
http://i30.photobucket.com/albums/c3...rogress050.jpg
getting the old rod ends off was a proper biyatch! Some WD40, bashing with a hammer & heat from a blow torch got em off though (I needed the rod end lock nuts).
http://i30.photobucket.com/albums/c3...rogress050.jpg
Heres the Corsa B PAS rack with new rod ends on
http://i30.photobucket.com/albums/c3...rogress055.jpg
http://i30.photobucket.com/albums/c3...rogress054.jpg
The knuckle on the rack that enters the cabin through the bulkhead is much larger on the PAS rack, no doubt due to the hydraulics within, so the bulkhead has to have the hole enlarged (see previous post) so I had to make a grommet type seal to go around the edge of the rack & bulkhead gap.
My can of WD was about the same dia as the knuckle on the rack, so I used the can as a template to cut a hole in a peice of thick rubber I had.
http://i30.photobucket.com/albums/c3...rogress058.jpg
Heres the grommet on the rack.
http://i30.photobucket.com/albums/c3...rogress059.jpg
Heres the rack being bolted onto the car.
http://i30.photobucket.com/albums/c3...rogress064.jpg
Ive had to work alongside some of my old mans shizzle in the garage. Probably the main reason why my progress is so slow. If he isnt rebuilding old bikes of his own, he's peering over my shoulder & telling me how I ought to be doing something.
http://i30.photobucket.com/albums/c3...rogress061.jpg
Theres another 5 bikes in the way too!
Good to see you on it mate
Very good work will use this thread when i finly get my new car loving it load keep up the great work
dude more gen needed on the rack...
ah u found some inspiration this weekend too! good work my friend.
Simps.
Well done Craig.
Its a modded Corsa GSi rack from a rally car . Any Corsa B rack will fit a Nova. The one I have is from a Nova rally car though. The track rods have been shortened to match the novas track (width) & the internals had been swapped for 'kwik' items which now has a lock to lock of 2.2 turns, compared to 3.75 turns for a regular Nova jobber. Nice!Quote:
Originally Posted by Benn
I was really lucky to pick up the rack off ebay about a year ago for less than ?40. Ive also got an (almost) brand new 12v Saxo pump. I got that for a pittence aswell, so I'm really chuffed with how much its cost.
All I need is the hydraulic lines making now, which I'm struggling with as my local Pirtek chap is dyslexic (putting it kindly).
Good Stuff !
Turrets look the nads, talking of which, you must have nads the size of basketballs cutting lumps that big out of its ass!lol
keep it up!