The Counts Track Day Nova Build

Glad you liked the video...i laughed so much and have started laughing again thinking about it! lol

Any way UPDATE time!!

After finally getting my hands on a Corsa B brake pedal set up on saturday (thanks AW06!) i could get on with fitting it, so here goes....

We started with this - the raw ingredients

http://i248.photobucket.com/albums/g.../engbay154.jpg

Then moved on the the car and the area of metal to be removed (Another note to myself just in case i forgot lol - luckily the only bit of rot on the bulk head was in this area!)

http://i248.photobucket.com/albums/g.../engbay155.jpg

Out it comes

http://i248.photobucket.com/albums/g.../engbay156.jpg

I then measured up and cut out a new piece of 3mm steel to fit the hole, resulting in a nice clean flat surface to mount the bias pedal box on

http://i248.photobucket.com/albums/g.../engbay157.jpg

And i tacked it in

http://i248.photobucket.com/albums/g.../engbay159.jpg

Once i was happy i welded the bad boy all the way round

http://i248.photobucket.com/albums/g.../engbay161.jpg

Cleaned it all up

http://i248.photobucket.com/albums/g.../engbay164.jpg

And stitched the front seam

http://i248.photobucket.com/albums/g.../engbay165.jpg

Once the new metal was in place i got on with fitting the pedal unit its self (as im going for an adjustable bias pedal box see below i don't need the servo or MC)

http://i248.photobucket.com/albums/g...85/CMB0338.jpg

I know i've replaced the above shelf with new thicker metal but, i don't think this is support enough for the brake pedal given all the support brakets i took out from the origional set up.
This added to the fact that i have hurd people with the corsa B set up complain that the bulk head flexes as you depress the pedal. This got me thinking what can i use to add extra support - i came up with this...

http://i248.photobucket.com/albums/g.../engbay168.jpg

I modified the original bracket to suit the corsa pedal, drilled a hole in the corsa pedal box and fitted the nova clutch arm (i modded it to fit properly later on in the fettling)

http://i248.photobucket.com/albums/g.../engbay169.jpg

This was the moc up fit just taked in place

http://i248.photobucket.com/albums/g.../engbay171.jpg

http://i248.photobucket.com/albums/g.../engbay185.jpg

There is more to come.....

Well done matey, really cracking on with this, cant wait to see the end result and also will it be the lighter of the two.... Yours or Oli's? lol

It looks like this from the other side and out of the car

http://i248.photobucket.com/albums/g.../engbay188.jpg

http://i248.photobucket.com/albums/g.../engbay189.jpg

As you van see on the back of the pedal box i welded in a small rectangle of 5mm plate to add support to the bracket and give a decent mounting point for the pedal

http://i248.photobucket.com/albums/g.../engbay190.jpg

http://i248.photobucket.com/albums/g.../engbay192.jpg

Then it was latte time again :gay:mmmmmmm

http://i248.photobucket.com/albums/g.../engbay193.jpg

As i said before the nova clutch pedal was just temporarily positioned until i got the bracket right, so once i had finished the bracket on the brake pedal i went on to make sure the clutch arm support was secure.

If you look at the picture below the bar to the corsa pedal from the clutch arm (the bit the clutch arm pivots on) doesn't sit flush up against the corsa pedal box, it sits at an angle this means you can't tighten it up properly.

http://i248.photobucket.com/albums/g...ngbay181-1.jpg

So to cure this i removed the original fitting from the nova with a hole saw and did the same with the corsa pedal so it would accept the original nova one giving a flat surface for the pivot bar to tighten up to as so

http://i248.photobucket.com/albums/g.../engbay194.jpg

http://i248.photobucket.com/albums/g.../engbay195.jpg

Welded it in

http://i248.photobucket.com/albums/g.../engbay197.jpg

And neatened it up

http://i248.photobucket.com/albums/g.../engbay198.jpg

Jobs a good un!

http://i248.photobucket.com/albums/g.../engbay202.jpg

http://i248.photobucket.com/albums/g.../engbay203.jpg

This also brought the nut and washer on the inside of the corsa pedal away from the moving parts on the inside (the piston to the bias pedal box)

And there is more....fecking 15 pic cr@p!!

Nice innovative touches there James, liking it alot matey!! That brake pedal assembly shouldn't budge at all, deffo a worth while idea.

Your going to be catching me up now! lol good work man

Once i was happy with that lot i went on to mod the pedal its self

http://i248.photobucket.com/albums/g.../engbay209.jpg

And a quick clean up - bish bosh!

http://i248.photobucket.com/albums/g.../engbay212.jpg

All fitted

http://i248.photobucket.com/albums/g.../engbay206.jpg

Then i turned the car round on its new found giant skate and fitted it with the roll over frame - can you guess what is coming next lol

Turned around

http://i248.photobucket.com/albums/g.../engbay213.jpg

http://i248.photobucket.com/albums/g.../engbay214.jpg

Frame on

http://i248.photobucket.com/albums/g.../engbay221.jpg

Crane on

http://i248.photobucket.com/albums/g.../engbay219.jpg

Up

http://i248.photobucket.com/albums/g.../engbay223.jpg

And over

http://i248.photobucket.com/albums/g.../engbay227.jpg

Giving great access to the underside

http://i248.photobucket.com/albums/g.../engbay230.jpg

This allows access to the seams on the underside of the engine bay that i haven't stitched yet and to tidy up a few areas that are a little scabby as well as to remove all the brackets from the brake and fuel pipes along with any other unwanted metal. Once ive done them i'll give it a good coat of stone chip and under seal.

Scabby areas - nothing serious mind

http://i248.photobucket.com/albums/g.../engbay232.jpg

http://i248.photobucket.com/albums/g.../engbay234.jpg

http://i248.photobucket.com/albums/g.../engbay235.jpg

And relax :D

Quote:

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Originally Posted by Jay

Well done matey, really cracking on with this, cant wait to see the end result and also will it be the lighter of the two.... Yours or Oli's? lol

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It will be very interesting to see who is lighter lol Oli's car will be a tough feet to beat though!

Quote:

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Originally Posted by nova ian

Nice innovative touches there James, liking it alot matey!! That brake pedal assembly shouldn't budge at all, deffo a worth while idea.

Your going to be catching me up now! lol good work man

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Cheers Ian i hope the pedal won't budge! Brakes are a very important area that may people seem to over look!
I will be catching you soon, do you think i will get mine finished first?? lol

very very nice like the pedal design and fabrication very impressive

excellent work as always James! Can't beat a good spit roast.

I will be giving you some more rep soon but apparantly I've STILL not spread enough around!!! lol