1987 Saloon Re-build.

Car related work carried out was:

Exhaust cleaned up ready to be used again.

http://i73.photobucket.com/albums/i2...l/STA60060.jpg

Gearbox removed from the engine and drained the transmission fluid out

http://i73.photobucket.com/albums/i2...l/STA60061.jpg

Clutch & starter out, starter needs new electrical connections

http://i73.photobucket.com/albums/i2...l/STA60062.jpg

Some transmission fluid did leak out

http://i73.photobucket.com/albums/i2...l/STA60063.jpg

My other cat was curious about what was going on

http://i73.photobucket.com/albums/i2...l/STA60064.jpg

New connections on the starter

http://i73.photobucket.com/albums/i2...l/STA60065.jpg

Timing chain cover removed for clean up

http://i73.photobucket.com/albums/i2...l/STA60067.jpg

http://i73.photobucket.com/albums/i2...STA60066-1.jpg

The cork seal around the altenator belt pulley is perished so will need re-newing. Wonder how hard that is going to be to find

http://i73.photobucket.com/albums/i2...l/STA60068.jpg

As I left things tonight

http://i73.photobucket.com/albums/i2...l/STA60069.jpg

Quote:

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Originally Posted by saloonwoody

looking good ;) lovin the workbench wish my garage was big enuf :( cant believe your not gonna leave it blue i was gettin inspiration for mine .http://i99.photobucket.com/albums/l2...d/SP_A0163.jpg

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I was going to leave it blue until I found the front valance, then everything changed.

Cheers,

Shaun

yours is gonna look the dogs when its done tho ..... jus cant wait to see it :)

Quote:

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Originally Posted by saloonwoody

yours is gonna look the dogs when its done tho ..... jus cant wait to see it :)

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Cheers mate :thumb:

O Why Is It Dark I Want To Get The Tools Out :(

Update from the last few days.

New clutch arrived

http://i73.photobucket.com/albums/i2...TA60049-10.jpg

On with it

http://i73.photobucket.com/albums/i2...STA60054-7.jpg

Wire brushed the gearbox to get off the corrosion ready for painting

http://i73.photobucket.com/albums/i2...TA60051-10.jpg

http://i73.photobucket.com/albums/i2...STA60052-9.jpg

Timing Chain cover painted

http://i73.photobucket.com/albums/i2...STA60053-7.jpg

Various bits and pieces cleaned and painted

http://i73.photobucket.com/albums/i2...STA60056-7.jpg

Gear linkage cleaned and painted

http://i73.photobucket.com/albums/i2...STA60059-2.jpg

Decided to re-position the cable assembly for the boot lock, mounted it on the back side of the panel so that I can trim this out easier.

http://i73.photobucket.com/albums/i2...STA60057-4.jpg

Had to bring the bootlid back to check it all still worked

http://i73.photobucket.com/albums/i2...STA60058-2.jpg

Will get paint for the gearbox today and hopefully my timing chain kit arrives so I can get started on cleaning up the engine.

Shaun

Excellent, glad to see its coming along nicely, although with all this time and effort, plus the paint job its almost as if the cars won't deserve the std 1.0 engine. If you see what I mean.

Quote:

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Originally Posted by novasteve

Excellent, glad to see its coming along nicely, although with all this time and effort, plus the paint job its almost as if the cars won't deserve the std 1.0 engine. If you see what I mean.

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I know, but I want to be different and the engine is in great condition.

This arrived today, but am stumped as to how to fit the cork ring seal into the timing chain cover.

http://i73.photobucket.com/albums/i2...TA60049-11.jpg

As you can see I have had an attempt at it with a hold punch and hammer, but nothing seems to be budging, not that I know how it comes apart, if it comes apart.

http://i73.photobucket.com/albums/i2...TA60052-10.jpg

Decided to leave it for now until I find out how to do it properly so the gearbox got a lick of paint.

http://i73.photobucket.com/albums/i2...TA60050-11.jpg

http://i73.photobucket.com/albums/i2...TA60051-11.jpg

Am kind of stuck for things to do now until I get the timing chain cover back on the engine.

great stuff.. keep it up. Nice nice.

If that ring seal comes out for the cork bit, try a socket with a face thats the right size as the inner peice, a peice of oak on top of the socket, and a sledgehammer :thumb:.

Looking nice.
Cant believe your keeping the 1L engine tho,Lol.

Yesterday, lifted the engine up onto the bench to fit the new timing chain kit and give it a clean up. Will replace the water pump, inlet, exhaust and rocker cover gaskets.

http://i73.photobucket.com/albums/i2...TA60051-12.jpg

http://i73.photobucket.com/albums/i2...STA60053-8.jpg

The gearbox got another lick of paint and removed the inlet and exhaust manifold and rocker cover for clean up and paint. The water pump seems ok, but will replace it as they're not expensive.

Exhaust manifold will get another coat of High temp paint today.

http://i73.photobucket.com/albums/i2...STA60055-6.jpg

Test fitted my exhaust on the car and all is well. Sourced the front pipe from ebay ?10 and the centre section from a Tyre & Exhaust fitter ?35. The rear box is the original off the car.

http://i73.photobucket.com/albums/i2...TA60052-11.jpg

Great work mate, absolutely love this little project!

wow i last looked at tis threadon page 4, my word youve been busy

Quote:

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Originally Posted by krobinson

Great work mate, absolutely love this little project!

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Cheers very much, I'll take that as a huge compliment considering the immaculate machine you are building.:thumb:

Quote:

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Originally Posted by Novalicious

wow i last looked at tis threadon page 4, my word youve been busy

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Not much else to do really lol

Assembled the gearbox back together.

http://i73.photobucket.com/albums/i2...STA60055-7.jpg

Exhaust manifold got another coat, inlet manifold got 2 coats (silver), rocker cover (black) and cleaned up the hot air feed.

http://i73.photobucket.com/albums/i2...STA60058-3.jpg

Managed to get my hands on a heavy duty bench vice

http://i73.photobucket.com/albums/i2...STA60056-8.jpg

http://i73.photobucket.com/albums/i2...STA60057-5.jpg

Watch you dont lose that engine down the back of your workbench lol

Tonight's progress is 24 hours behind for 2 reasons.

There was a delay getting my gaskets and water pump and the radiator let go in the Astra, so had to get stuck in to that last night. Still no where forward as the radiator I got today isn't the correct one.

http://i73.photobucket.com/albums/i2...STA60063-1.jpg

So this lies abandoned on the driveway and the wife is having to use my car as she works further away than me.

Also, check the condition of this, pretty fooked.

http://i73.photobucket.com/albums/i2...STA60062-1.jpg

?212 for a new one from vauxhall, needless to say this will be repaired closer to the time when the Air-Con will be required.

So tonight, got the engine off the bench and put back together. Was easier getting it down than lifting it up, funny that!

http://i73.photobucket.com/albums/i2...STA60055-8.jpg

New bits

http://i73.photobucket.com/albums/i2...STA60056-9.jpg

http://i73.photobucket.com/albums/i2...STA60057-6.jpg

http://i73.photobucket.com/albums/i2...STA60058-4.jpg

Great Idea to compress the clutch in order to remove the clips.

http://i73.photobucket.com/albums/i2...STA60059-3.jpg

http://i73.photobucket.com/albums/i2...STA60060-1.jpg

http://i73.photobucket.com/albums/i2...STA60061-1.jpg

Very little left to do now, but I'm sure I'll find bits here and there.

like the colour scheme looks ace

Progress has dwindled to nothing now as the car is now in the paint shop and everything else has been done.

The last few jobs I had to do were, grind off all the rust from the anti-roll bars and paint them, clean up the steering rack and paint and remove all the windscreen sealant from the rubber seal.

http://i73.photobucket.com/albums/i2...STA60065-1.jpg

http://i73.photobucket.com/albums/i2...STA60064-1.jpg

http://i73.photobucket.com/albums/i2...STA60066-2.jpg

Shaun.

Looks good, so you definetaly gone for jamaica yellow then? I cant remember tbh! lol

Yup, defo going yellow. Can't wait to be honest.

WOW this is going to look amazing when its painted and all put back together mate, hope to see it in the flesh some time, keep up the good work shaun.


iain

Can't wait to see it painted

How long we got to wait?

Quote:

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Originally Posted by vaughanmc

Can't wait to see it painted

How long we got to wait?

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It shouldn't be too long before there is some paint on the car. Had to source a new doorskin as I damaged the one I got.

Looking forward to seeing the paint on mate, i have been coming back every now and then just in case i missed the paint job.

Scott

Had to dig this out and give it a clean and paint.

http://i73.photobucket.com/albums/i2...wipermotor.jpg

Have now run out of things to do, will have to do Christmas shopping now........

Quote:

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Originally Posted by scott.parker

Looking forward to seeing the paint on mate, i have been coming back every now and then just in case i missed the paint job.

Scott

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I'll be going to get pictures of the car during the painting process, it was held up last week due to the door skin, but the new skin has arrived and things should start moving again.

Cheers,

Shaun.

looks good, hope you get the work back underway shaun.


iain

i like that alot m8 always likerd the saloon lol

Sent you a wee pm mate, good to see the Nova's still coming along nicely!!!

nooooooo
i'v just read 20 pages hoping to see it all painted up
as a reward, hows it coming on any news on paint
looks like a top shell keep it up some hard work gone in to this
im finding it hard to just finish off tidying my engine/bay up
muchos respect

Wonderful read this Shaun.

I like the way you document your method - more important than a finished article pic in my book.

It would have been nice to see some real horsepower under the bonnet but understand your reasoning.

Personally, why the bodywork is being painted I would have rolled the arch lips so that you can go to wider wheels whenever you want.

So far the new door skin has been fitted, just needing welded up and smoothed. Will get pics of better progress in due course.

Cheers guys,

Shaun.

Engine looks great, keep up the great work mate!

Absolutley fantastic little car you have there mate, when i joined this forum i wasnt keen on nova saloons or mk1's but i love them just as much as the mk2 now, be brilliant to see the car once its painted up, this thread and many others are inspiring me to keep working on my car even tho it's freezing in my garage.

looks fab m8 nice to see more saloons about they r the way ahead if u need a thin rear bumper will poss b intrersed in swap as i am after the one u have of the mk2

when we gonna see some paint on it ???