Joff's Nova Turbo Project

Well, this weekend I have been on with getting the front bumper to fit correctly around the intercooler.

I have had to build up the lower lip in order for it to fit around the bottom of the intercooler. This was my
first real go with fibreglass and I am please with the initial results. The bottom lip needs smoothing and
sanding smooth but it is the right shape and profile.

http://www.elsamak.karoo.net/front1a.jpg

I'll also need to trim some of the aperture for the intercooler in order that I can fit the mesh around the
intercooler to give it a bit more protection.

I also got a bargain on ebay this week which I picked up yesterday after the grand prix from a guy in
Rotherham - 4 almost new and 1 new Michelin 195/45 16's for ?98 :o

http://www.elsamak.karoo.net/tyres1a.jpg
Well more updates later !

Joff

this car is going to be awesome!

keep it coming! :D

looks sweet so far keep up the good work!

this rebuild looks absolutly amazing mate, was considering the corsa dash my self, but think ill give it a miss after seeing that lol


very nice mate .. some great work has gone into that 8)

More smoothing of the front bumper this week - but GOOD NEWS - I can now finish off the inner wings as I needed a die grinder to sort out some welds in a corner - this arrived !!

http://www.elsamak.karoo.net/Compressor1a.jpg

It means that I can now run an air powered die grinder, PLUS I now have an impact ratchet gun, shultz waxoyl gun, tyre guage and air gun!!!

More updates after the weekend

Joff

absalutly amazin man lookin forward to following your progress

Bit more of an update - not much really happened this week end due to famly illness - I've had my rocker cover,
nos bottle and camcover acid dipped to get rid of the powder coating :-

http://www.elsamak.karoo.net/aciddip1a.jpg

I've also now made up some brackets welded onto the rear strut brace to hold the nos bottle ...

http://www.elsamak.karoo.net/bottle2a.jpg

Should fit nicely above the planned ICE install ....

http://www.elsamak.karoo.net/bottle1a.jpg


Cheers for now - I'm off to be I'm knackered!!!

Joff

looks excellent mate

how much did you pay to have the rocker and cam cover acid dipped as im trying to get mine cleaned up at the min :lol:

Got the three items acid dipped for a tenner from a mate on a guvvy job - they also do powder coating which is going handy for the rear beam!

Joff

looking good joff.
how much is now left to do?

Up date on things to do prior to the spray shop -

- finish off the inner wing smoothing behind the drivers side headlamp
- finish off the front bumper so it fits round the intercooler and ensure the mesh fits OK
- fit front wings so panel gaps are acceptable
- finish off rubbing down accessories for sprayshop - wing mirrors, handles etc

These jobs should take another few weeks so should be off to the spray shop by beginning of June!!!

Cheers

Joff

getting along really well, looks amazing already, cant wait for the final piece....

Had a thought this morning - I have done away with the front towing eye so I can't strap down the front for transportation to the sprayshop or once I am up and running hold the car down on the rollers at Well Lane Turbo.

Therefore I have made up a couple of additional brackets with two new towing eyes - one at the end of each of the chassis legs- I've lowered them sufficiently to enable the straps at the rolling road to hook up under the front bumper.

http://www.elsamak.karoo.net/hook1a.jpg

Lots of weld to keep them in place and another job sorted - just need some new Argoshield as my bottle now only has about 50psi left!!! (should be c2500 psi when full!)

Joff

Thats a good idea that.

Well ........ success ...... Ive now fitted the front bumper complete with mesh and grille surround.

The stainless steel mesh is very thick and was a real pain to shape round the corners of the intercooler at the two bottom corners.

A couple of bits of box section, a vice and some brute strength sorted it out!!!!

http://www.elsamak.karoo.net/mesh1a.jpg


Should look great once the shell has been to the spray shop!!!

http://www.elsamak.karoo.net/mesh2a.jpg

enjoy!
Joff

I want. That looks sweet. Is that a gsi bumper or a kingdom one?

looks really good mate

the towing eye idea was a good one aswell :lol:

Its a Kingdom one thats been modified with a bigger mouth to fit the intercooler in!!!!

The quaility wasn't brill and has taken me ages to get all the nicks and marks out of the bumper ready for spraying.

I'm quite pleased with the results but are unsure of how low the front end will be in relation to the ground clearance! Time will tell - its a bit late now to change!!!

Joff

looking good joff when do you think its gonna be out?

looks like some good thoughts gone into that.
atleast you thought of the problem before you came up trumps at a later date.

Another update.......

Been making the final preperations on the shell ready for the spray shop in a few weeks time .... whoooow !!!!!!!

Been looking at the chargecooler kit I have aquired ..... I needed to find somewhere to mount the pump
and header tank. Had a bit of a brainstrain on this and decided to mount the pump behind the wiper motor
next to the blower motor and the header tank fits nicely behind the offside suspension turrett.
Also cut a couple of holes to route the pipework through the bulkhead as seen in the pic .....

http://www.elsamak.karoo.net/pump1a.jpg

And heres the header tank .....

http://www.elsamak.karoo.net/header1a.jpg

I need to get in contact with radtec who sorted out my intercooler as I need a front radiator with an
additional small integrated radiator for the chargecool system - more money .... ho hum!

Cheers

Joff

hmmmmmmmm chargecooled 8) *drool*

Why are you fitting a charge cooler as well as your big FMIC? All it will do is restrict the airflow and speed.

FMIC and chargecooler ....... I want to crank the boost up a bit but still keep a fair bit of reliablity - a cooler charge should help - I think this will be a try and see exercise - if it doesn't really work then I will use the header tank for use in a intercooler spray system.

Joff

Joff i will be running a big fmic and about 2+ bar or boost. I dont expect any problems with boost temps. PS a charge cooler begins to act like a charge warmer as the engine gets hotter and your boost temps will rise.

Amen to that...

I remember my charge cooler being very poo after 2 minutes of hard driving.. lol!

That was Courtenay's twin core one.. I was told it wouldn't cope with much increase in boost hence why I decided to bin it.

We have a date for the spray shop ........

18th June 2005 !!!!

So its all hands to the pump to get the shell ready. I've prepped the bonnet, drilled holes and a cut out for the scoop and mounted it with the help of my mate Chris :drinking: cheers! First time the cars had a bonnet on in 2 years :P !!

http://www.elsamak.karoo.net/shell24a.jpg

Need to hoover out all the crud from the shell especially in the sills as theres lots of metal dust in there from the grinding I've been doing around the shell.

Made sure the scoop fits - looks OK with the pressed in vents!
http://www.elsamak.karoo.net/shell23a.jpg

Been thinking about the chargecooling issue - I'm going to try it to see how it goes but will possible consider a large second header tank to increase the coolant capacity which may help>

Joff

How much was the stool-type intercooler in that bottom picture? :idea:

About ?3 from Ikea - cheeky!!!

:2gunfire: :grab:

there's a little mans that sits on it and pushes his feet along the ground flintstone style lol.

this is gonna be one hell of a car.

Well we're in the final stages of prep work - heres one of my alloys prepped up - just another 3 to go (and the centre caps!!) !!!!

http://www.elsamak.karoo.net/voodoo1a.jpg

The Pirelli's are getting binned as they are really crap in the wet and they are so old the rubber is now cracking - not good!

9 days to go !!!!!

Joff

9 days.... don't put yourself under any pressure mate!!!!!

nice one joff hope it all goes to plan for you :lol:

cool mate, cant wait to see the finnished work.

just wondering tho mate, you say you want to charge cool it now, that will mean that all those chassis mods you have done to the front pannel to fit you intercooler will be a waste as surely your not going to use both an intercooler and a charge cooler.

I'm going to trail run both intercooler and chargecooler and run some inlet and outlet charge temp sensors to see the results, if they make little difference I'll bin the chargecooler and use the header tank for a water to intercooler spray kit - so some of the kit will get used either way!

Anyone recommend some water jets that would be suitable - just as a back up!!!

I hoovered the shell out last night. When I started the bag was empty and when I was finished I emptied the bag again to discover that I had hoovered up just under a 1kg of crap!!!!

There was loads of cr@p in the sills which I sucked up using a long pipe - these sills have never been cleaned out since I got the shell - back in 1989 .

Order of events are now :-

- Spray shop
- Apply sound deading
- Waxoyl shell
- Pedal box and heater matrix
- 1st fix of wiring loom
- make up all brake pipes
- petrol tank and pipes
- rear suspension

And thats the first few jobs - sounds easy but the wiring loom needs LOTS of work before putting in the shell.

Cheers

Joff

amazing car mate you're really putting in the effort with it

where abouts are you

i live in scarborough sounds like i'm not far from you if you live near beverly

Quote:

---

Originally Posted by joff-turbo-nova

Anyone recommend some water jets that would be suitable - just as a back up!!!

---

Give Lisa and Laurence a ring - Laurence has just fitted this set up from a ********** intercooler spray to his corsa C20LET -Works off a washer pump/bottle and cost less than 20 quid from the main dealers !!!

Produces a fine mist of water from the three jets !


I'm sure he'll tell you the car and part number

http://www.corsasport.co.uk/carimages/2675/dcp_0776.jpg


Cheers

Dave

Looking good Joff, always great to see someone taking so much pride :wink:

I was going to say mate, could you not just make a set up using the washer bottle and the rear wash pump? At a guess you will be doing away with the rear wash/wipe. Bit dodgy using water from the header tank.

Good luck mate. Karl