CG's rebuild thread. PROJECT COMPLETE

Tonight I was chuffed!

http://i30.photobucket.com/albums/c3...rogress038.jpg
Me rad arrived!

http://i30.photobucket.com/albums/c3...rogress041.jpg
I checked it fits so I didnt have to return it...

http://i30.photobucket.com/albums/c3...rogress037.jpg
Another coat of Satin black on the powerbox. Didnt primer it though & regretting it already..

http://i30.photobucket.com/albums/c3...rogress039.jpg

Fuel unions bolted home.
http://i30.photobucket.com/albums/c3...rogress031.jpg
http://i30.photobucket.com/albums/c3...rogress032.jpg

Things feel like they are gelling together a bit now

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Originally Posted by craig green

http://i30.photobucket.com/albums/c3...rogress038.jpg

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Quote:

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Originally Posted by westwood

wow, this is the biggest rad that looks like a screen we've eveeer fitted

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:cool:

Just spent the last 2 nights trying to clean some kind of undeseal substance off from under my rear arches. Its still tacky after a year of being on there & wont allow any other products to be applied. Its just messy as funk & I'm really pissed off with it.

The only thing that seems to shift it is carb cleaner. My hands are a mess, I've used shed loads of workshop tissue & Wednesday night I'd totally had enough. When I shut the garage door I didnt want to see the car again......

Well I spent about 3 hours under the clocksucker last night. 3 empty cans of carb cleaner, 2 ruined toothbrushes & mild neck ache later.... I'm happy with the passenger side wheel well & rear chassis leg. Its dry & free from scummy underseal. Tonight (Fri) should see some nice seam sealer going on after a coat of zinc primer.

Gotta do it all again on the drivers side though! http://www.migweb.co.uk/forums/images/smilies/doh.gif I'm somewhat happier than yesterday though.

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Originally Posted by craig green

update with pics!

ILovin my new tail pipe...
http://i30.photobucket.com/albums/c3...pics/wip10.jpg

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what make/model of exhaust is that because i like it alot

it looks the same as what i have matt...
which would be.. piper s/s with 3.5" tail outwardly rolled..
:thumb:

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Originally Posted by matthew172

what make/model of exhaust is that because i like it alot

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IIRC its a custom system mate, made to fit a small block 16v.

Nice one craig, good to see you got a rad(is it the one from bypartsbuy? Or halfords?) good choice removing the vertical bar that goes between the slam and crossmember, as its a right bastid to get the rad down past the dispak, exhaust manifold etc. Lol

Exhaust is a custom one I bought 2nd hand. Its comparable to the ones on a lot of the N.W Novas. Big 4" outwardly rolled Cossie style tail pipe & nice stainless pipes & welds. I thought it was a JP but have been told they are different. Could be a 'Blue Flame' one, I dunno? I like it though.

The fr panel brace was removed for the Courtenay intercooler that was on there. Obviously no longer fitted. Yeah slipping the rad in was always a biatch when I had to do the head gasket etc.

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Originally Posted by craig green

Exhaust is a custom one I bought 2nd hand. Its comparable to the ones on a lot of the N.W Novas. Big 4" outwardly rolled Cossie style tail pipe & nice stainless pipes & welds. I thought it was a JP but have been told they are different. Could be a 'Blue Flame' one, I dunno? I like it though.

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Does look proper quality, just what i was after :( lollollol

Havent done a great deal since last week, got a couple more pics uploaded though.

More rear end action.... Paint is going on as I clean.

http://i30.photobucket.com/albums/c3...BILLING052.jpg
http://i30.photobucket.com/albums/c3...BILLING054.jpg

Ive just picked up an exhaust manifold gasket so the front end will begin to be fitted up (bumpers & lamps etc).

Oh and this is a L hand drive bonnet release lever & cable, so I can mount the brake bias valve on the drivers side location.

http://i30.photobucket.com/albums/c3...BILLING055.jpg

Above the speaker pod.

http://i30.photobucket.com/albums/c3...ts4sale024.jpg

good work lad. keep it up

Still doing bits here & there. Nothing to report as such though. Cleaned out my outer CVs this week & regreased them. (cant afford new ones & they are newish. 10k). Also routed lots of hoses & cables. Found a 1.2i ECU mount will be ideal to mount the C16XE ECU above the glove box. No MDF or forget nails required!

I've got hold of an airbox, C16SE or late GSi non AFM engine, quite rare & new out of the bag fresh , with a Courtenay foam panel filter.

http://i30.photobucket.com/albums/c3...EATURES001.jpg

http://i30.photobucket.com/albums/c3...EATURES002.jpg

It'll need tweaking to meet the TB nicely, but I think it can work.

Just got some manifold studs & nuts, so I can fit that & I've literally just signed for a strut brace that has been delivered.

Looking good, how far off is it from running? Might be the only nova at the first offical SW meet lol

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Originally Posted by Ash

Looking good, how far off is it from running? Might be the only nova at the first offical SW meet lol

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A while off yet. Next year would be a good bet as I doubt I'll put it on the road over the winter. We'll see. The upcoming tasks should actually go a lot quicker than the cleaning & painting I've been doing for last couple months.

That exhaust looks the same as my JP one.....

air box isn't that rare, they come on sri's too..

maybe rare is, due to most people chucking them in the bin, in favour of a cone filter :roll:


its coming to gether now, look's good :thumb:

Nice progress Craig, gonna colour code your inner arches?

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Originally Posted by S t e

air box isn't that rare, they come on sri's too..




its coming to gether now, look's good :thumb:

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Yeah I meant rare as in . Tricky to come by.

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Originally Posted by SRimon

Nice progress Craig, gonna colour code your inner arches?

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;)

I think the exhaust is a JP but cant confirm it.. so wont brag. LOL

oooh, looks like its getting there Craig :D nice one for the tip off about that engine in Cov aswell mate :thumb:

Just a quick qeustion, what do you have planned for you washer bottle? As i see youve removed the mounting bracket?

Cheers dude.

Corsa bottle in the scuttle tray. Needs some support to mount on, but an easy solution hopefully. I'll get a pic sometime.

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Originally Posted by craig green

Cheers dude.

Corsa bottle in the scuttle tray. Needs some support to mount on, but an easy solution hopefully. I'll get a pic sometime.

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Aaaah good plan!! Ive got a Mk1 Clio bottle knocking about here, just finding a pair of Pug 409 wiper arms is proving quite hard lol

409! 406? surely.

Heres the Corsa bottle in place.

http://i30.photobucket.com/albums/c3...ss-sale004.jpg

http://i30.photobucket.com/albums/c3...ss-sale006.jpg

I picked up exhaust manifold studs & the copper nuts from Vauxhall today. Crack on with front end assembly now.

hey that looks pretty good Craig :D

Ahh, 409 wipers are special ;) the 406 ones are different :D had a look today an cant find my Clio bottle, think i binned it :( but i got a corsa sitting outside......

Never heard of a 409..

Its coming together a bit more now. I've got my strut brace so I can drill the holes to route the PAS pipes through the firewall.

Still need to buy up all the brake lines which is a ball ache for me!

Liking the corsa wash tank,hmm, good idea.
That gives somewhere to fit a catch tank with the washer one gone,Lol.

Does it clear the wiper linkage?

motoring on now! I remember hearing that local motor factors will make up brake lines for you if you give them a template. I know your lines are ending up somewhere differant but you could get them to make them so far and finish of the rest yourself on the car, if they leave a meter or so spare. Failing that, grow a money tree and buy full braided ;)

Washer bottle looks spot on btw. Good work

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Originally Posted by craig green

Never heard of a 409..

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LMFAO neither have i lol its mean to say 405 lol

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Originally Posted by Ash

Failing that, grow a money tree and buy full braided ;)

Washer bottle looks spot on btw. Good work

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That is the plan.... seedling has just poked through the soil!

Thanks. :)

Nothing much to report other than I removed the tie bar & TCA so I can set about getting the last nut off I've rounded off. The ones going through the ball joints etc.

http://i30.photobucket.com/albums/c3...ss-sale015.jpg

Its the hole to the right (inside one) thats got the rounded nut in. Minimal accesss with limited tools.
I've taken the dremel to the holes & opened them up where needed as the plates are a tad skew-wiff, thats the issue with the rounded nut.

Other News; I got hold of a pair of small rosejoints to use for my alternator tension adjuster.

http://i30.photobucket.com/albums/c3...ss-sale022.jpg

Another one of those problems that I was avoiding as I wanted a neat solution.

Thats a good idea on the Alternator craig, thatll make it uber easy to set up on your own, rather than the 3 tools 2 hands normal effort lol

Did I mention my exhaust manifold is on? With new GM studs & copper nuts.

http://i30.photobucket.com/albums/c3...ss-sale023.jpg

http://i30.photobucket.com/albums/c3...ss-sale020.jpg

It looks like its coming along nicely, some good mods you got there. when she out on the road!

Im liking the rj alternator tensioner, cool solution. Where did you get the joints from?
Manifold looks cool, i'd move the lambda tho.

Rose joints are from my local rally/motorsport stockist. Cost me a fiver for both!

You can get them on ebay & places like Rally Design do them too. I got them by chance really. I was pricing up a Tran-X diff. I just need to get a couple belts to calculate the length of adjustability etc.

One is L/hand threaded & the other is a normal R/hand thread, so by turning the centre one way it will shorten the adjuster & likewise visa versa.

OK. Had a busy weekend doing other stuff & going to Eurofest at Castle Combe (top time as always).
But I also managed a few hours in the garage.
I put a few coats of gloss black on my bottom arms (TCA's) & the tie bars & also put 1 coat of smooth Hammerite in the front wheel arch. I put some seam sealer around edges & joins that form a water trap. Should help keep any water out of box sections etc.

Tiebar & brkt.
http://i30.photobucket.com/albums/c3...s/dscn2140.jpg

Bottom arm.
http://i30.photobucket.com/albums/c3...s/DSCN2138.jpg
http://i30.photobucket.com/albums/c3...s/DSCN2139.jpg

1st coat of paint in wheelarch.
http://i30.photobucket.com/albums/c3...s/DSCN2143.jpg
1st coat looks pretty crap as it doesnt cover very well. (2nd coat is now on).

Hopefully I will assemble the tie bars & TCA's with the new bottom ball joints later tonight & fasten it all back in place with the passenger side driveshaft & new gearbox, d/shaft seals.

Pics of 2nd coat of paint, better coverage & the paint loses its transparency.

http://i30.photobucket.com/albums/c3...s/dscn2147.jpg

http://i30.photobucket.com/albums/c3...s/DSCN2145.jpg

Coming along nicely Craig, nice work. Great idea with the alternator tensioner. Safely completed in time for next year then, much else to do?

It would be nice to see pics of the painted inner arches as I'm thinking of doing mine but didn't know if it would look too red...

EDIT- Looks a lot better than the 1st coat, you may have made up my mind lol

I was in two minds wether to paint the inner arches Red or re-do them Black, however the floor pan ended up being done Red as it was already Red from the factory anyway, so it all got a few coats of smootherite in the end.

I just need an alt belt to calculate the min & max movement for the adjuster & then I'll draw up the adjuster bar & get a local machinist to make it up. (hopefully they will have an M8 L/hand tap)

I really want the car ready before the spring, hopefully have it shaken down & MOT'd before I want to start using it. I've been to a few track days recently as a spectator & I'm fed up of feeling left out, plus I need to lose my track virginity soon. I've been wanting to start doing track days for years but money issues & reliability seem to always get in the way. Obviously next year is a key year for Nova enthusiasts & I'm not going to miss it for the world.