The Counts 1.7 TD GSI nova

Quote:

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Originally Posted by Adam

The clutch on my astra slipped a bit too, it wasnt exactly brand new though.

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my brothers is brand new and still slips lol

I also had slippage issues when giving mine big beans, usually when carrying a load up a slope or a hill, mine was only boosting at 19psi though but i imagine they dont take well to the extra torque upped fuel and boost produces, mine was a new clutch aswell, but only did it to me a handful of times and behaved after that lol

I know I will have issues as my 1.7td corsa slipped after some left foot down and that clutch had only done a few thousand miles hence the reason for the hunt for another option.
The standard friction plate has a diameter of 200mm which is the same as a 1.6 16v or very close iirc which is tiny for the 200 odd lb ft of torque I plan on putting through it ( the c20xe's friction plate is 220mm wide iirc and they only produce 149lb ft or what ever it is) so I'm going to see if I can machine my Td flywheel to suite an xe clutch and use an updated one.

Also didn't Baxter have an f28 fitted??? So what fly would he have used for that??

Baxter, F28? LOL.

Quote:

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Originally Posted by craig green

Baxter, F28? LOL.

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That was kinda my point lol

looking at that flywheel i cant see any reason why you cant machine it so that its basically a copy of an XE flywheel :) and i think it was the supercharged x16xe he planned to fit an f28 to

Quote:

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Originally Posted by Spudly

I also had slippage issues when giving mine big beans, usually when carrying a load up a slope or a hill, mine was only boosting at 19psi though but i imagine they dont take well to the extra torque upped fuel and boost produces, mine was a new clutch aswell, but only did it to me a handful of times and behaved after Andy set the cable properly ;)

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Great build,this will be spot on.Nice attention to detail aswell

Baxter just had a std box afaik.
F28 would take some messing about to fit, because the size of the input shaft(bigger than f16/f20 etc) means you would have to spend hours looking for clutch part catalogues looking for a suitable friction disc.

I have an LUK book at home if you wanna borrow it..lol

I meant to comment on this the other day.

A, its really good to see Craigs shell living on!
B, love the fact its going to be different! Didn't baxter have nearly 200BHP out of his 1.7TD?

Thanks Simon

According to baxters sig on vxON it was 212 with an f28

see here:

[IMG]file:///C:/DOCUME%7E1/Tracy/LOCALS%7E1/Temp/moz-screenshot-3.png[/IMG][IMG]file:///C:/DOCUME%7E1/Tracy/LOCALS%7E1/Temp/moz-screenshot-4.png[/IMG]http://i248.photobucket.com/albums/g...I/untitled.jpg

either machine your flywheel for an xe setup, but use a c20let pressure plate this will give the clamping force required but the splines for an f16/18/20 box etc

of if your feeling flush speak to ttv racing and they will make you a billet item

if there's enough face and the clutch will bolt up ok, machine the fly.

Todays activities began with the removal of the rear axle (it was craigs disk axle and he sold it on so it had to go) - nice to meet you btw Chris.

Back end in the air

http://i248.photobucket.com/albums/g.../NovaTD316.jpg

http://i248.photobucket.com/albums/g.../NovaTD317.jpg

Axle off

http://i248.photobucket.com/albums/g.../NovaTD318.jpg

Luckily i had a spare anyway so i slipped that on

http://i248.photobucket.com/albums/g.../NovaTD319.jpg

Axle swap...done!

http://i248.photobucket.com/albums/g.../NovaTD320.jpg

Whilst i was messing around with that i found the MOT failure of the day - just another repair!

http://i248.photobucket.com/albums/g.../NovaTD321.jpg

Putting that to one side i focused back on the main task in hand - the engine bay modifications and repairs

This needed sorting

http://i248.photobucket.com/albums/g.../NovaTD322.jpg

So i fashioned this repair section

http://i248.photobucket.com/albums/g.../NovaTD324.jpg

like a glove

http://i248.photobucket.com/albums/g.../NovaTD323.jpg

Gave it a clean up

http://i248.photobucket.com/albums/g.../NovaTD325.jpg

Along with the inside of the chassis leg

http://i248.photobucket.com/albums/g.../NovaTD326.jpg

Tacked it in

http://i248.photobucket.com/albums/g.../NovaTD329.jpg

And welded it in fully (this was a pain in the ass due to the amount of crispiness all over the surrounding material)

http://i248.photobucket.com/albums/g.../NovaTD330.jpg

http://i248.photobucket.com/albums/g.../NovaTD331.jpg

After giving that a quick clean off and a prime i started to tidy the leg up as i wanted all the cutting and grinding to be done before i welded the td engine mount in.

This is how i left it

http://i248.photobucket.com/albums/g.../NovaTD327.jpg

Crispy

http://i248.photobucket.com/albums/g.../NovaTD328.jpg

A little cleaner with primer

http://i248.photobucket.com/albums/g.../NovaTD333.jpg

Then i went on to do some marking of more unwanted material, so i had some clean metal to weld to

http://i248.photobucket.com/albums/g.../NovaTD332.jpg

chop chop

http://i248.photobucket.com/albums/g.../NovaTD335.jpg

http://i248.photobucket.com/albums/g.../NovaTD336.jpg

http://i248.photobucket.com/albums/g.../NovaTD337.jpg

Getting there

http://i248.photobucket.com/albums/g.../NovaTD338.jpg

Doesn't that look better

http://i248.photobucket.com/albums/g.../NovaTD339.jpg

http://i248.photobucket.com/albums/g.../NovaTD340.jpg

http://i248.photobucket.com/albums/g.../NovaTD342.jpg

Once i was happy here it was time for the boost pipe repair section

I gave this some further fettling ready for its insertion

http://i248.photobucket.com/albums/g.../NovaTD341.jpg

Clamped it to the car and cut through it

http://i248.photobucket.com/albums/g.../NovaTD343.jpg

Another hole!

http://i248.photobucket.com/albums/g.../NovaTD344.jpg

I cleaned the edges and some other rust holes/patches

http://i248.photobucket.com/albums/g.../NovaTD345.jpg

http://i248.photobucket.com/albums/g.../NovaTD346.jpg

Then turned my attention to the engine mount its self

drilled some holes for puddle welding the bottom edge to the cars outer chassis leg

http://i248.photobucket.com/albums/g.../NovaTD334.jpg

Tacked in

http://i248.photobucket.com/albums/g.../NovaTD347.jpg

http://i248.photobucket.com/albums/g.../NovaTD348.jpg

And began to weld it in

http://i248.photobucket.com/albums/g.../NovaTD349.jpg

http://i248.photobucket.com/albums/g.../NovaTD350.jpg

The chassis leg its self needed quite a lot of cleaning to find clean metal hence the gap around the td leg section, i will probably weld it all up then clean the welds up V them out again then cap them to finish them off properly.
I was unable to get any further today due to important house buying related commitments so hopefully there should be some more progress to follow tomorrow :thumb:

Should look pretty much factory once the welds are ground back and painted, very neat work. :thumb:

It's quite worrying where rot can hid on shell even if you think there clean and rot free..

But looks like your well on top of it now mate, fair play for doing all this.
Keep it up.

Scott

I'm sitting in a damp patch.

u even had sunshine.. i mean blimmey..

Looks great James!!

looks a good project, and the standard of your work is excellent :thumb:

Quote:

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Originally Posted by peester

u even had sunshine.. i mean blimmey..

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No such luck today though :(

hay i recognise that astra, and that garage looks very familiar, hang on a minute thats my astra lol :), can`t wait to c this nova finished, im hoping to get the astra dyno`d at pv :)

onca again stunned by your builds mate.Keep it up James.

Nice work James, will keep an eye on this :thumb:


Although it makes me miss my TD... :cry: :cry: :cry:

Youve got some skills James! Impressive work

As Sunday was a was out i was determined to get at least something done on monday what ever the weather!

Fortunately the sun was out to begin with so i cracked on

I ground back the welds on the newly inserted td chassis leg section, then V'd them out to take a final cap off

http://i248.photobucket.com/albums/g.../NovaTD351.jpg

http://i248.photobucket.com/albums/g.../NovaTD352.jpg

http://i248.photobucket.com/albums/g.../NovaTD353.jpg

V'd out

http://i248.photobucket.com/albums/g.../NovaTD354.jpg

http://i248.photobucket.com/albums/g.../NovaTD355.jpg

Then just as i was about to lay the first line of weld it started to pissit down ffs, i thought funk this its time for some sort of circus gypsy tent as so

http://i248.photobucket.com/albums/g.../NovaTD356.jpg

This kept the rain off everything thank funk. Anyway it was a short shower so onwards with the welding

http://i248.photobucket.com/albums/g.../NovaTD357.jpg

http://i248.photobucket.com/albums/g.../NovaTD358.jpg

Happier with that i moved on to the small section i had cut out to get at the inner skin

Held in place with a magnet while a tacked it home

http://i248.photobucket.com/albums/g.../NovaTD359.jpg

Tacked

http://i248.photobucket.com/albums/g.../NovaTD361.jpg

And done (not the prettiest admittedly lol)

http://i248.photobucket.com/albums/g.../NovaTD362.jpg

http://i248.photobucket.com/albums/g.../NovaTD363.jpg

Moving swiftly on I welded up the top edge of the chassis leg insert

First below the turret

http://i248.photobucket.com/albums/g.../NovaTD360.jpg

Then all the way down the top of the leg, yes there was fire and it popped and spattered like a bastid!

http://i248.photobucket.com/albums/g.../NovaTD364.jpg

http://i248.photobucket.com/albums/g.../NovaTD365.jpg

Now it was jigsaw time as i needed to do something with the large hole were the rotten metal used to be

First and easiest repair section tacked in place

http://i248.photobucket.com/albums/g.../NovaTD366.jpg

http://i248.photobucket.com/albums/g.../NovaTD367.jpg

Then i began at the back of the hole below the turret with the first of my home made repair sections, the section in question is directly above my earth return clamp in the pic below.

http://i248.photobucket.com/albums/g.../NovaTD368.jpg

I crafted this shape after some careful measuring

http://i248.photobucket.com/albums/g.../NovaTD369.jpg

Cleaned up the weld behind the repair section

http://i248.photobucket.com/albums/g.../NovaTD370.jpg

Manipulated the metal into shape

http://i248.photobucket.com/albums/g.../NovaTD371.jpg

http://i248.photobucket.com/albums/g.../NovaTD372.jpg

Getting there but a little more needed

http://i248.photobucket.com/albums/g.../NovaTD374.jpg

http://i248.photobucket.com/albums/g.../NovaTD375.jpg

Tent time again, fecking rain!

http://i248.photobucket.com/albums/g.../NovaTD373.jpg

Once i was happy with the final shape i drilled some holes were the repair section meets the chassis leg lip so i could puddle weld it in later on

http://i248.photobucket.com/albums/g.../NovaTD376.jpg

And tacked it in to position - not to bad a fit

http://i248.photobucket.com/albums/g.../NovaTD377.jpg

http://i248.photobucket.com/albums/g.../NovaTD378.jpg

Moving down the leg i was getting frustrated with yet more rust so out came some more metal

http://i248.photobucket.com/albums/g.../NovaTD379.jpg

Giving me the perfect opportunity to douse the inside of the chassis leg with acid etch primer

http://i248.photobucket.com/albums/g.../NovaTD380.jpg

http://i248.photobucket.com/albums/g.../NovaTD381.jpg

While the primer was drying i cut up some more metal to fill the hole

http://i248.photobucket.com/albums/g.../NovaTD382.jpg

welding it in good and proper

http://i248.photobucket.com/albums/g.../NovaTD383.jpg

This gave me a much better base to build the rest of the repair off of

Metal cut

http://i248.photobucket.com/albums/g.../NovaTD384.jpg

http://i248.photobucket.com/albums/g.../NovaTD385.jpg

Bent

http://i248.photobucket.com/albums/g.../NovaTD386.jpg

http://i248.photobucket.com/albums/g.../NovaTD387.jpg

And tidied in to shape

http://i248.photobucket.com/albums/g.../NovaTD388.jpg

Tacked in ready for the next section - i thought small sections would be easier....

http://i248.photobucket.com/albums/g.../NovaTD389.jpg

The beginnings of the next section

http://i248.photobucket.com/albums/g.../NovaTD392.jpg

Fettled

http://i248.photobucket.com/albums/g.../NovaTD393.jpg

http://i248.photobucket.com/albums/g.../NovaTD394.jpg

Inserted

http://i248.photobucket.com/albums/g.../NovaTD395.jpg

On to the next

http://i248.photobucket.com/albums/g.../NovaTD396.jpg

http://i248.photobucket.com/albums/g.../NovaTD397.jpg

Looking a little better

http://i248.photobucket.com/albums/g.../NovaTD398.jpg

Another small section

http://i248.photobucket.com/albums/g.../NovaTD399.jpg

http://i248.photobucket.com/albums/g.../NovaTD400.jpg

finally the last piece of the puzzle

http://i248.photobucket.com/albums/g.../NovaTD402.jpg

http://i248.photobucket.com/albums/g.../NovaTD403.jpg

Frankenstein's monster is complete

http://i248.photobucket.com/albums/g.../NovaTD404.jpg

Happy that i was getting there i began to weld the sections in permanently

http://i248.photobucket.com/albums/g.../NovaTD405.jpg

http://i248.photobucket.com/albums/g.../NovaTD406.jpg

The section above the current return clamp was a right t w a t to do as it kept trying to destroy itself

http://i248.photobucket.com/albums/g.../NovaTD407.jpg

http://i248.photobucket.com/albums/g.../NovaTD408.jpg

But i got there in the end

http://i248.photobucket.com/albums/g.../NovaTD409.jpg

http://i248.photobucket.com/albums/g.../NovaTD410.jpg

You may think WTF has he done but after a clean off with the sanding disc it began to look better

http://i248.photobucket.com/albums/g.../NovaTD411.jpg

http://i248.photobucket.com/albums/g.../NovaTD412.jpg

http://i248.photobucket.com/albums/g.../NovaTD413.jpg

More sanding to blend the edges

http://i248.photobucket.com/albums/g.../NovaTD414.jpg

http://i248.photobucket.com/albums/g.../NovaTD415.jpg

http://i248.photobucket.com/albums/g.../NovaTD416.jpg

Smoother still but much more to do

http://i248.photobucket.com/albums/g.../NovaTD418.jpg

http://i248.photobucket.com/albums/g.../NovaTD419.jpg

I had to call it a day here unfortunately as i was due to make the joyous journey back down south so i welded up the bottom of the td chassis leg section and slapped some primer on it to keep the weather off it, even now the leg doesn't look to bad with some paint on it

http://i248.photobucket.com/albums/g.../NovaTD421.jpg

http://i248.photobucket.com/albums/g.../NovaTD420.jpg

I then sealed the front panel - job done!

http://i248.photobucket.com/albums/g.../NovaTD422.jpg

aye.. good skills.

Excellent fab skills as all ways James

Cheers Chaps hopefully next weekend will see the appearance of something other than this fcuking chassis leg and you will have something more interesting to look at lol

Keep up the good work buddy!

Funk dude, your fab skills/work is awesome. Great work.

Lols until the last few pics it looked like you were patching the leg up with bits of giant mechano lol

Top fab skills fella!

Great Work Count