1.6 8v T project

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31-10-08, 09:58 PM
BRoadGhost

Thank god you're not removing the heater claiming the payoff in weight loss is worth it then.
31-10-08, 10:42 PM
almond

Quote:

Originally Posted by scott.parker

True Adam, but as said Mike's mate could only get 3mm at the time and it was FREE.

Scott

good enough reasson for me:D

looking good fella. what would we do without grinders :confused:lol
01-11-08, 04:50 PM
mikec123

I had no problem working with 3mm steel.Never have! I only used 3mm because it was free!!!!!!!!
16-12-08, 05:24 PM
scott.parker

Small update!

Right as me and mike are out of work now he (we) have more time on our hands,so Ive popped over to help out a few times in the last few weeks,and here's a mini update on things.

Mike's mate Simon has finished all the welding to the car (without any more fires :D ) and the inner wings are all done (mike has pics of this I'm sure)
The bay is prepped and ready for spraying over Christmas,i hope to have a go at the spraying my self..:)

So back to last week, i popped by and asked if he needed a hand with anything,and we decided while the engine and box are out and separated they should get cleaned up/painted etc, so thats what we set about doing so..

Box was cleaned of all grime by mike,now we start the prep, main prep was done using drill wire brush attachments etc,then some finishing with sand paper/wet n dry, GM's finish from the cast is so so shocking:wtf:

Prep of box.
http://img241.imageshack.us/img241/6...06smallnd5.jpg

not much has been prep in this pic,you can see theres still some grime/dirt on it,and Ive not yet took the rust/paint of the black cover yet.
http://img241.imageshack.us/img241/6...09smallje4.jpg

While cleaning, we noticed these codes,Ive got no idea what it is,but sure some of you do lol
http://img241.imageshack.us/img241/5...07smallkt4.jpg

http://img241.imageshack.us/img241/8...13smallxy2.jpg

http://img241.imageshack.us/img241/3...16smallzy6.jpg
16-12-08, 05:43 PM
scott.parker

Check the **** in the casting!:roll:

http://img241.imageshack.us/img241/4...14smallye2.jpg

http://img241.imageshack.us/img241/9...17smallof9.jpg

http://img241.imageshack.us/img241/8...18smallnz6.jpg

http://img241.imageshack.us/img241/1...19smallce3.jpg

http://img241.imageshack.us/img241/9...25smalllx3.jpg

All the paint/rust sanded off..

http://img241.imageshack.us/img241/6...26smallef9.jpg

Zinc primer on the bottom/diff cover, filler primer on the top where it was badly pitted in the casting,and what ever els we could find got slung on it lol

http://img241.imageshack.us/img241/4...28smallfu9.jpg

And bit of drying under the lights..
http://img241.imageshack.us/img241/5...31smalllo0.jpg
16-12-08, 05:54 PM
scott.parker

Forgot to say these pictures are all taken using my new phone, samsung toco (touch screen) 5 mega pixel, lol Ive got a new digi cam for Christmas thats 10 mega pixel.

Anyway, it was onto some more coats of primer,before quick dry then first top coats.
Diff plate,under box in first coat etc

http://img241.imageshack.us/img241/2...33smallhx9.jpg

http://img241.imageshack.us/img241/1...36smallic5.jpg

First coat's of Hammerite smooth silver brushed onto box casing.

http://img241.imageshack.us/img241/3...66smallza0.jpg

http://img241.imageshack.us/img241/8...65smallxa8.jpg

http://img241.imageshack.us/img241/6...67smalllk2.jpg

While i was there the next day Mike had started to clean up the block/head and turbo/exhaust manifold etc, while i was holding the exhaust down pipe and he was cleaning i noticed it seamed to be moving about allot,so we investigated (as it was heat wraped) and found the down pipe was split:eek:

Hence to say Mike was not happy,and we called it a day at that..

(ref fro Mike LOTNS)

http://img241.imageshack.us/img241/1...60smallwj3.jpg

So at some point he's now got to get the down pipe re-made.

Scott
16-12-08, 07:09 PM
Mike

Looking good Mike/Scott.

Sorry about my phone cutting you off the other evening mate, its been playing havoc the last few days!!! You get a chance to looks at any of the downpipes I told you about mate?
16-12-08, 07:18 PM
scott.parker

Yeah couldn't seen any worth going to the hassle of buying one, mike's just going to try get one made.
16-12-08, 07:28 PM
Mike

Ok mate, was worth a try though chap.
17-12-08, 10:58 AM
mikec123

cheers for the pics scotty:thumb: Good camera on that phone!
18-12-08, 09:46 PM
wilson_sri

Looks to be coming on well!

Dont suppose you have any detailed picture of how your turbo to AFM hose was?
18-12-08, 11:20 PM
scott.parker

Wilson, i don't think it had a GM set up(if you mean like the standard AFM box etc?) Nova Niel who use to own the engine before did a lot of custom bits to it, and I'm not 100% sure if thats what you mean or not, i could find a pic of the engine if it would help?

Scott
24-12-08, 05:05 PM
mikec123

A few more updates i undersealed the splash guards and in the arches

http://i275.photobucket.com/albums/j...g?t=1230134221

Started to clean the engine up
Here it is with the exhaust manifold off

http://i275.photobucket.com/albums/j...g?t=1230134381

I then took the inlet manifold off and cleaned it with my wire brush attachment that fits in my drill
http://i275.photobucket.com/albums/j...g?t=1230134431

Then i gave it 2 coats of hammirite smooth silver
http://i275.photobucket.com/albums/j...g?t=1230134524

http://i275.photobucket.com/albums/j...g?t=1230134524

I also painted my rocker cover with a heat resistant paint then im going to spray it the same colour as the car!

http://i275.photobucket.com/albums/j...g?t=1230135420

I have just taken my car to a friend of mine and iam spraying the engine bay on saturday!
24-12-08, 05:35 PM
scott.parker

Dude not sure if you meant to,but the last two inlet pics are the same?

Looks all good though, and that paint on the rocker looks quite nice as it is lol might use that on mine!

So are you spraying the bay on sat or am still going to try it?

Scott
25-12-08, 08:29 PM
wilson_sri

Quote:

Originally Posted by scott.parker

Wilson, i don't think it had a GM set up(if you mean like the standard AFM box etc?) Nova Niel who use to own the engine before did a lot of custom bits to it, and I'm not 100% sure if thats what you mean or not, i could find a pic of the engine if it would help?

Scott

Mines isnt standard gm set up either. Got a hose rungs from the turbo to the standard AFM. No air box though, goes to a k&n air filter.

I think its the same set up as it has the hole cut in the wing. Pics of engine would help.
26-12-08, 12:57 PM
scott.parker

Quote:

Originally Posted by wilson_sri

Mines isnt standard gm set up either. Got a hose rungs from the turbo to the standard AFM. No air box though, goes to a k&n air filter.

I think its the same set up as it has the hole cut in the wing. Pics of engine would help.

Not the best pic, but im sure mike has better.

http://img241.imageshack.us/img241/5...2007006xj6.jpg

http://img241.imageshack.us/img241/5...2007006xj6.jpg

Scott
15-01-09, 08:36 PM
mikec123

Pic of the inlet with injectors back in ready to back on the engine

http://i275.photobucket.com/albums/j...g?t=1232048192
16-01-09, 06:58 PM
mikec123

Pics of the engine bay which i sprayed up over xmas

http://i275.photobucket.com/albums/j...g?t=1232128559

http://i275.photobucket.com/albums/j...g?t=1232128602

http://i275.photobucket.com/albums/j...g?t=1232128646

http://i275.photobucket.com/albums/j...g?t=1232128692
16-01-09, 07:35 PM
Jay

Looking good mate, i like fresh paint :)
16-01-09, 11:00 PM
scott.parker

Look really good, ill have to pop over and have a gander!

Also dude you should ask on here about them fuel pressure regulaters.

Scott
16-01-09, 11:03 PM
craig green

Bloody nice paint job on the engine bay by the looks of things.

keep at it matey.
20-01-09, 06:23 PM
mikec123

Cheers for the comments. i put the inlet back on the engine yesterday just got to get my new clutch, have my flywheel lightened and sort out a new downpipe then the engines ready to go back in.Lack of money has ground me to a hault at the moment.:eek:
20-01-09, 08:39 PM
jimbob-mcgrew

the mighty 1.6 8v.. with added turbo! very nice.
any idea what the brake per ton is mate ? i reckon its prob around 220, depending on interior bits, which must be rapid.
hell of alot of resto work gone into this :thumb:
im liking the solid engine mounts too.
21-01-09, 03:25 PM
mikec123

cheers buddy havent got a clue what the brake per tonne is.:thumb:
21-01-09, 06:11 PM
scott.parker

Quote:

Originally Posted by jimbob-mcgrew

the mighty 1.6 8v.. with added turbo! very nice.
any idea what the brake per ton is mate ? i reckon its prob around 220, depending on interior bits, which must be rapid.
hell of alot of resto work gone into this :thumb:
im liking the solid engine mounts too.

Taken with a lrge pich of salt, this is from http://www.letstorquebhp.com/calculator.asp

Power at Flywheel (BHP) : 191
Weight without Driver (KG) : 790
Power to Weight Ratio (BHP Per Ton) : 245.65
0- 60 (Secs) : 5.050
0- 100 (Secs) : 12.54
60- 100 (Secs) : 7.49
Quarter Mile (Secs) : 13.46
Terminal Speed (MPH) : 103.58
Drag Strip Quarter Mile (Secs) : 13.26
Drag Strip Terminal Speed (MPH) : 105.51

But hey, we wont know till we test it he Dude! :thumb:

Scott
22-01-09, 11:00 AM
mikec123

Cheers dude. Im impressed with that lets hope it does something near that:thumb:
22-01-09, 02:10 PM
Edd

as said engine bay looks good. as im building a 1.6 8v turbo il keep a eye on this one.
22-01-09, 05:19 PM
mikec123

Be interesting to see what you are up to. Do you have a project thread?:thumb:
22-01-09, 07:44 PM
ben doodar

nice work gone into that,good write up aswell. love the idea of a 1.6 8v turbo, bet its ace to drive. ive often thought about turboing my 2.0 8v, but i can imagine the mapping manegment being too expensive. i know it says you bought the complete engine with ecu etc. what sort of money do you think you would pay for the manegment + mapping etc.
does anybody use megasquirt? my mate who is into his mk2 golf's said alot of them boys use mega squirt on the golf forums. my boss's friend uses a mega squirt system in an off roading landrover aswell, but i never get chance to pick his brains about it.

also did you ever go to a vauxhall/ford show in coventry maybe 3-5 years ago. sure it was at a county show ground or somthing...
22-01-09, 08:25 PM
jimbob-mcgrew

oo scott u cheated on the weight ! lol
just did a calculation with a 70 kilo driver sat in it, comes out 225 brake per ton.
thats still serious brown trousers from my point of view lol
23-01-09, 10:41 AM
Edd

Will be starting a project thread very soon. got lots of bits already.
23-01-09, 04:10 PM
scott.parker

Quote:

Originally Posted by ben doodar

nice work gone into that,good write up aswell. love the idea of a 1.6 8v turbo, bet its ace to drive. ive often thought about turboing my 2.0 8v, but i can imagine the mapping manegment being too expensive. i know it says you bought the complete engine with ecu etc. what sort of money do you think you would pay for the manegment + mapping etc.
does anybody use megasquirt? my mate who is into his mk2 golf's said alot of them boys use mega squirt on the golf forums. my boss's friend uses a mega squirt system in an off roading landrover aswell, but i never get chance to pick his brains about it.

also did you ever go to a vauxhall/ford show in coventry maybe 3-5 years ago. sure it was at a county show ground or somthing...

Ill try answer some for you mate, Neil who use to own it spent £K's on the engine/setup etc, I think for the DTA and all the parts gathered to get it working was near to £3000 (not sure though) so it's not really worth while doing it (unless your lucky like him, engineer @Rolls-Royce) and have the money to do so..
20ltr 8v turbo’s are really good, or even on TB’s! That’s worth thinking about doing.

And I think I know the show your on about mate, I’ll dig you out a pic.

Scott
23-01-09, 09:36 PM
ben doodar

am not going to bother messing with the 8v, alot of people think there not worth while, but they do go well, and easy to work on in a nova.
but for them extra few ponnies, im just going go for a redtop.
yh i thought it would be a costly affair turboing the 1.6 really cool tho.
thats why i asked about the megasquirt as it can be done on the cheap, just out of interest really.

yh see if you can dig the pictures out from the show, you may remeber my mates 1.7td nova on the mobile rolling road there? chucking out alot of black smoke haha.
26-01-09, 11:43 PM
scott.parker

Small up date on behalf of mike.

Well today I went round to mikes, the plan was: take of rear suspension, disconect brakes/hand brake, and remove rear beam so it can be de-rusted Polly bushed and painted up!

So off we go...we jacked the car up, put it on axle stands then undid the nuts from the top the shocks, making sure threes a jack under the beam to take the weight.
The undone the shocks from the beam, and removed the springs (we were both confident we know how to get to this point)LOL

Now we were a bit in un charted waters as neither me more Mike had take the rear brake lines apart, more disconnected a hand brake set up before!

So quite a bit of fiddling and swearing later (WD40 was needed big time LOL 18 years of sh1te) we got the brake lines disconnected by undoing them where they join to the flexi lines from the solid part (bracket on the rear beam)

Now were stumped! Neither of us knows how to get the handbrake cable off from the back of the drums; bit of luck I had a Hanes nova manual in back of my car.
Bit of reading and swearing and we soon had them disconnected (lets hope they go back the same)
so then it was time to undo the bolts to the beam and drop it..

http://img222.imageshack.us/img222/2...23smallhh5.jpg

http://img222.imageshack.us/img222/2...24smallyg1.jpg

Now I know some of you can do this in your sleep, but for us it was all unknown and a dam bit of fun.
So we though huh good bit of work done, at this point mike went of to make some tea.
So I started looking at the rear inner arches, I found some dark loose under seal (you can see it in one of the other pics) I pulled at to find it was a huge lump of filler covered over with sh1te loads of under seal!!
Well I was shocked and so was mike, well we both thought sod it he's done the front end, so let’s see what lerking under the rear arches is!

Let the rot fest begin!!

http://img222.imageshack.us/img222/6...25smallpj1.jpg

http://img222.imageshack.us/img222/4...27smallnj4.jpg

http://img222.imageshack.us/img222/1...26smallzu5.jpg

Iffy sping plate (can you buy these??)

http://img222.imageshack.us/img222/3...28smallhp4.jpg

How would you go about fixing/platting the chassis leg part??

http://img222.imageshack.us/img222/6...42smallxi4.jpg

These are all of the off?drives side.

Now the near side looked better at first inspection...

http://img222.imageshack.us/img222/6...29smallwq1.jpg

Opps!

http://img222.imageshack.us/img222/9...30smallog8.jpg

Then the nasty supprise we hoped we wound not find..

http://img222.imageshack.us/img222/5...31smallxe8.jpg
http://img222.imageshack.us/img222/4...44smallsh2.jpg

Mike Needs some advise on the best way to tackle sorting this bit, how do you go about plating it? can you buy the spring monuts??
26-01-09, 11:54 PM
scott.parker

Mike then said well may aswell get grinding it out! so he set to it straight away lol fair play!
I kept and eye on the iside for him as some sparks were going through into the car (dont want another fire)

http://img230.imageshack.us/img230/1...32smallcr3.jpg

http://img230.imageshack.us/img230/1...34smallce4.jpg

http://img230.imageshack.us/img230/9...37smallvr4.jpg

http://img230.imageshack.us/img230/7...33smalltq5.jpg

http://img230.imageshack.us/img230/8...38smalljo3.jpg

Nice...:roll:

http://img230.imageshack.us/img230/4...41smallow7.jpg

http://img230.imageshack.us/img230/6...40smallsh1.jpg

So weather pending the other side will get attacted as well tomo!

To be honest im just as gutted as mike is, as we never thought it would be this bad, but theres no going back, and might as well do a propper job, so what started as a small restoration is now a BIG one lol

Least the engine looks nice now..:D

http://img230.imageshack.us/img230/7...45smallek4.jpg

Keep your head up dude, i'll help as much as i can.

Scott
26-01-09, 11:58 PM
Steve

Sh!t that is a nasty surprise! good to see it hasnt put you off, especially with all the other work
thats gone into it. Engine does look good :cool:
27-01-09, 12:07 AM
scott.parker

Quote:

Originally Posted by Steve

Sh!t that is a nasty surprise! good to see it hasnt put you off, especially with all the other work
thats gone into it. Engine does look good :cool:

lol just a bit, i dont think he wants to take the skirts off as he's too worried what we'll find...
27-01-09, 01:20 AM
ben doodar

fair play to you both for the hard work going in, i rember when i started to find more n more rot on my car, p!ssed me off no end, really dis-hearten's you. i hate welding rotten cars, it really aint a nice job!! so credit to you both for your hard work..
27-01-09, 10:22 AM
mikec123

cheers for the pics dude! as Scott said need a little advice as to what to do with the chasis.:thumb:
27-01-09, 07:21 PM
Adam

Jesus, thats quite a bit of rot! :(

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