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done a bit more over the last few days -
Saturday 07/10/2006
Went to my local Vauxhall dealer (where Nova Freak works - v handy!) and got a set of new front brake lines made up for next to nowt!
Stripped down and repainted the rest of my brake system including the master cylinder (big black disk thing) and my caliper sliders - nice and shiney and black now - really look the part!
Sunday 08/10/2006 - Tuesday 10/10/2006
Operation VW boot release!
As you may know I'm planning on installing a Golf MK5 boot release system in to my replacement Nova hatch. The Golf MK5 release system in concealed in the actual badge and lifts up with a very smooth sexy action. the mechanism is a simple micro switch and simply releases the solenoid when lifted. I need to work out the electrics re this linking it into my central locking at some point but thats much later down the line (and where the leccy boys on NL come in - he he!)
My task over the last few days was to work out how to fit the actual release mechanism (the badge) into my smoothed boot.
I'd already made the basic smoothed panel and it was treated and left ready for skimming with filler to make it nice and smooth.
For those that have seen a mk5 Golf, the badge sits a little proud of the surface of the boot and has a raised circle round it which is blended back into the bood surface. I need to try and replicate this in some way.
The 1st task was to cut the hole - the diameter ofthe badge to the outer support was 123mm - I drilled out a circle and spent most of Sunday filing it round. It didnt need to be 100% because the hole would be covered with a resin insert to secure the mechanism later on. The main thing to check for was that the badge itself fitted and protruded through the boot.
The next step was to make a support. I started by making a resin base which would sit on the inside of the boot around the hole. This would be the anchor point for the mechanism and will be secured by a suitable bonding material (probably sikaflex because its very strong).
The next step was to make a casing for the badge housing. This needed to be accurate because the mechanism itsel has a rubber ring which stops water getting into the boot insides. Therefore I had to ensure the resin housing was a snug fit and suitably sturdy. The best way to do this was to cover the entire mechanism in masking take and cover the whole thing in resin and fibreglass. There is the final result (after trimming and sanding)-
an inside view
http://img.photobucket.com/albums/v1...a/DSCF0016.jpg
from the outside
http://img.photobucket.com/albums/v1...DSCF0015-1.jpg
the mechanism in its housing
http://img.photobucket.com/albums/v1...a/DSCF0017.jpg
The outside didnt need to be pretty because you wouldnt see it - the main part was the inside - the circular housing section needed to be smooth. Ther are one or 2 air bubbles on the rim however these will be smoothed with filler prior to painting.
The next step was to join the base that would attach to the boot to the housing ensuring the badge was lined up correctly - both in the way it sat (it opens by pressing the top and lifting up so it needed to be level or it would look v stupid!) and in the amount it stuck out proud (it needed to be an equal distance all round).
Once set, chopped fibre matting (fibrol) was applied to the housing and it was then stuck to the base (which was secured in place by double sided tape as a temporary fix).
Heres the result just after bonding the 2 parts -
http://img.photobucket.com/albums/v1...a/DSCF0031.jpg
http://img.photobucket.com/albums/v1...a/DSCF0029.jpg
and with the mechanism in situ -
http://img.photobucket.com/albums/v1...DSCF0032-1.jpg
You can see from this pic how it protrudes - the idea now is to lay over a fibreglass matt up to the hole and bond it from the outside making s water tight seal then skim and smooth with filler - applying if necessary the raised edge that runs round the badge.
http://img.photobucket.com/albums/v1...DSCF0033-1.jpg
This pic shows the badge in relation to the rest of the boot -
http://img.photobucket.com/albums/v1...DSCF0024-2.jpg
Obviously I will be replacing the VW badge (whish is actually just held on by 2 small clips and some double sided tap!) with either a Vauxhall or Opel badge (probably the latter).
:thumb:
Tasks tomorrow (my day off) - providing the rain holds off - to seam seal my engine bay so I can plan the respray of the bay itself.
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All good stuff ade.
Fibrol rocks!
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another great days work ade. i wish the rain would hold off here so i could get on with some work.:thumb:
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Nice to see its still comin on nicely!
L
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looking good, liking the idea of the boot release.
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really trick idea with the VW realise ade
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lol iv just spent an hour and a half reading all of this - its really coming along ade! keep up the good work mate :)
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cheers!
Tuesday 11/10/2006
Another day off - weather absolutely sh1te (so unable to get my engine bay seam sealed) however did a bit more work on the boot.
I cleaned up the inside of the housing for the boot mechanism - smoothing it and making it tighter to the actual badge section. I then sealed the rim of the hole using sikaflex and rivets and bondedthe resin constructed housing to the boot from the inside.
I'll post some pics of it done tomrrow once its cured.
Next task is to clean up the excess bonding material and then smooth the outer section making it a smoothed boot.
Once smooth I'll consider adding a grab handle type detail - not like the original one though but similar to the new grille badges on the latest models (minus the badge - see below). Where the V section is is where the boot badge will be...
I'm also looking at getting one of these for the front (although they currently retail at ?80 from vauxhall)
http://img.photobucket.com/albums/v13/danga/1a_1.jpg
Prefer it with an opel badge though...
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Be interesting to see what that will look like on the front of a nova, hmmmmmmmm
L
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Thursday 12/10/2006
Started off this evening by fitting the new poly bushes into my suspension.
See earlier in the thread for how to remove the old bushes.
I'd painted up my track arms a few weeks ago with no rust satin black paint - several coats and its now fully cured.
Heres the bushes I'm using from Polyflex - nice and orange!
http://img.photobucket.com/albums/v13/danga/susp7.jpg
They come in 2 halves for easy fitting
http://img.photobucket.com/albums/v13/danga/susp6.jpg
Theyre easy to fit - simply spray a litle wd40 or similar lubricating oil onto them to help get them in. Stick one half into the hole and push all the way in -
http://img.photobucket.com/albums/v13/danga/susp5.jpg
Then part insert the other one and part insert the metal rod. Then using a G clamp and 2 bits of wood so as not to damage said bushes, clamp up the other side fully to get a nice tight fit -
http://img.photobucket.com/albums/v13/danga/susp4.jpg
http://img.photobucket.com/albums/v13/danga/susp3.jpg
http://img.photobucket.com/albums/v13/danga/susp2.jpg
et voila -
http://img.photobucket.com/albums/v13/danga/susp1.jpg
Takes about 5 minutes.
Also painted up mt Gmax strust - the spring seats were a tad rusty - just surface though so I degreased them and gave a coat of no rust -
http://img.photobucket.com/albums/v13/danga/susp8.jpg
So with the exception of my new Astra ATE brake calipers and discs the whole inner arch will be nice and black - with anthracite alloys should look pretty cool.
:cool:
