Benn's on going build

From here, i used the Nova pedal bit that bolts to the bulk head, Trimmed it down to use as a main support. Much cutting tiny amounts off, line up and repeating.


Getting it lined up.


http://img.photobucket.com/albums/v3...psubv6ol8h.jpg


Grip in place, try and tack it in so its stronger enough to remove, but where it is you can see the join.. Que much arching and wire waste and very minimal tacking and much burning of my arm/wrist and swearing.


Got it out, and welded the f**k out of it.


http://img.photobucket.com/albums/v3...psphdb0qny.jpg


http://img.photobucket.com/albums/v3...psyueumk5p.jpg


Added in some 90deg angled metal some extra strength.


http://img.photobucket.com/albums/v3...psl68yg9so.jpg


http://img.photobucket.com/albums/v3...psbem896is.jpg


Not the tidiest welding, but lots of penetration and strong as ****.


http://img.photobucket.com/albums/v3...psot8egd1o.jpg


Now that bit of pedal assembly is kinda just pressed together. So added some weld on for me strength.


http://img.photobucket.com/albums/v3...psdapc2ech.jpg


http://img.photobucket.com/albums/v3...pstywjs2ks.jpg


http://img.photobucket.com/albums/v3...pst4cudyab.jpg


http://img.photobucket.com/albums/v3...ps0qzvg4qa.jpg




http://img.photobucket.com/albums/v3...psdphb3h2s.jpg

Got it so hot, the plastic insert in this bit melted.


http://img.photobucket.com/albums/v3...psi1gmapqd.jpg


http://img.photobucket.com/albums/v3...psjhdynlza.jpg


http://img.photobucket.com/albums/v3...pstxuhtfck.jpg

Now i read in to support the clutch arm pivot bar. two threads, two different ways. I went with one..


Which this was done.. To the Corsa set up,


http://img.photobucket.com/albums/v3...psubsgtkdb.jpg


Then you cut this away from the Nova parts..


http://img.photobucket.com/albums/v3...pswt54ot12.jpg


To the do this,


http://img.photobucket.com/albums/v3...psbhywi4e6.jpg


So it would look like this, but in the Corsa bit.


http://img.photobucket.com/albums/v3...pstyziqwyw.jpg


See where it's going? You weld the Nova bit in to the Corsa bit to hold the clutch arm in place.


Now this is were it went wrong. Fit the clutch arm back in and i got this...


http://img.photobucket.com/albums/v3...psbh6zrs2d.jpg


Why it is so far over?? Would never be able to weld the bit in to that..


http://img.photobucket.com/albums/v3...pssywytpcv.jpg


Back to my ref photo... Bugger.
On the thread i was going with, James had cut the battery tray out and re-placed with a flat sheet, doing that he had move the Corsa pedal box over.. I didn't see that at the time. F**k.

Go to the other thread and see how he's done this bit. He (cheers IaIn) had used the Nova clutch support arm and welded that to the underside of the scuttle/battery tray. I liked that but wanted it removable with the rest. So i started cutting.
Bracket cut down.


http://img.photobucket.com/albums/v3...psgfxgifn1.jpg


http://img.photobucket.com/albums/v3...pssmogxd8j.jpg


http://img.photobucket.com/albums/v3...psz80czcvj.jpg


Lined up.


Spotted in place.


http://img.photobucket.com/albums/v3...psolkex8io.jpg


Remove so it can be fully welded in.
http://img.photobucket.com/albums/v3...psjyeisjak.jpg


As you can see there's a bit of a gap, so used the rest of the bracket to fill. As it was nice thick metal i could get it glowing and it would be strong. strong as f**k


http://img.photobucket.com/albums/v3...psu3jogrks.jpg


http://img.photobucket.com/albums/v3...ps5vzvcp6i.jpg


Inside welded too.


http://img.photobucket.com/albums/v3...ps4w3f8mu3.jpg


http://img.photobucket.com/albums/v3...psjvwuefnt.jpg


Cleaned up.


http://img.photobucket.com/albums/v3...ps4jhtmsgg.jpg


http://img.photobucket.com/albums/v3...psys9bu1ld.jpg


http://img.photobucket.com/albums/v3...pslc9urnzs.jpg


After it was ground down, i tested the clutch pedal, it was good. I then tested it was a bar and it doesn't move at all. Perfect.


Coat of direct to metal gloss black.


http://img.photobucket.com/albums/v3...psla8qfdyi.jpg




http://img.photobucket.com/albums/v3...psc2xw6k5m.jpg


Painted all the pedals up to mate and look better.


http://img.photobucket.com/albums/v3...psqqxopizk.jpg

http://img.photobucket.com/albums/v3...psyix1xomf.jpg


With that dried in the 60deg! Temps in my conservatory.. Burn my hand on one bit!
Everything was refitted to mod the pedal.
This bit is annoying and it's in and out over and over... The pedal is a mix of Corsa top and Nova bottom, Cutting and welding... Got it in where i thought was right. but need to go back and mod it again as it's to high at the mo (i found on the drive to PVS)

http://img.photobucket.com/albums/v3...psxzpgkzkl.jpg




Welding... Oooo look at the heat.


http://img.photobucket.com/albums/v3...pshw7baaip.jpg


Cleaned the other side up, welded the join.


http://img.photobucket.com/albums/v3...psybenfmej.jpg


The added plate either side over the weld. then painted.


Next was to weld the servo base plate in.


Lined up with bolts.


http://img.photobucket.com/albums/v3...ps9p7bd4ca.jpg


Seam sealed in after a coat of etch.


http://img.photobucket.com/albums/v3...pscxi8qdkx.jpg


You can see the bit i cut out at the start here and how far away it now is..


http://img.photobucket.com/albums/v3...pswhscvdv9.jpg


I worked the sealant under the edge and across the front to reshape the water way around it...


http://img.photobucket.com/albums/v3...pscxi8qdkx.jpg




While it was drying i fitted clinch/rivnuts in...


http://img.photobucket.com/albums/v3...psp6hurwne.jpg


To hold my battery power point.


http://img.photobucket.com/albums/v3...ps5ymgiprm.jpg


And one here...


http://img.photobucket.com/albums/v3...psfhwpmcnw.jpg


To hold..


http://img.photobucket.com/albums/v3...psf4z0von8.jpg

Drilled the bulk head brake union.


http://img.photobucket.com/albums/v3...psqskg5c4a.jpg


The big hole was where the loom entered the car, which isnt used now...


http://img.photobucket.com/albums/v3...ps9rwjruhx.jpg


Isn't needed so might as well remove it.


http://img.photobucket.com/albums/v3...psbcnf7kge.jpg


That's where a small fire occurred.


http://img.photobucket.com/albums/v3...psrha3h0f3.jpg


Not fun when your laying on the engine and have to rush and dive under the dash.


Last check.


http://img.photobucket.com/albums/v3...pseujrdtsv.jpg


Time for paint.


http://img.photobucket.com/albums/v3...psimdlauxn.jpg


http://img.photobucket.com/albums/v3...psz2q5rgj8.jpg


http://img.photobucket.com/albums/v3...pstqsjc9sb.jpg

On to my own hell.


Took of my nice brake lines... Binned them. As none of them are gonna be any use and started a fresh.... OH :(


http://img.photobucket.com/albums/v3...psqpuecvqz.jpg


Stress level 7.


http://img.photobucket.com/albums/v3...psuyk7plco.jpg


Brake line bulk head fitting, 6 quid each! Thank you to every who offered me tips on the right pipe flair to fit these. fitted 3, 2 for the pair of front lines, 1 for the single rear line i run.


http://img.photobucket.com/albums/v3...ps3xz0215y.jpg


Stress level Omega (11)


http://img.photobucket.com/albums/v3...psq3zgz9bn.jpg


Heart attack stress level. All because i want brake lines perfect (they arnt) that wont be seen!


http://img.photobucket.com/albums/v3...pssd7uv6nl.jpg


http://img.photobucket.com/albums/v3...pshoniwcn1.jpg


Painted the servo.


http://img.photobucket.com/albums/v3...psjwhlqug5.jpg


http://img.photobucket.com/albums/v3...pspu8dovdo.jpg


Lines back out and all painted.


http://img.photobucket.com/albums/v3...psi7aqigvh.jpg


Started to fit them and found my drivers side bulk head fitting is right on the back of the fuse box! So had re-drill the hole, move it along to clean it and re make the frigging line. Loom holes annoys me as it's not that tidy.


http://img.photobucket.com/albums/v3...psbimsz52g.jpg


Lines refitted.
Note new longer line.


http://img.photobucket.com/albums/v3...psby7mx4tp.jpg


These two arnt 100% the same, but close.


http://img.photobucket.com/albums/v3...psmveiyqq9.jpg


http://img.photobucket.com/albums/v3...psn5k1oljo.jpg

Where i'm working..


http://img.photobucket.com/albums/v3...psbayidyuq.jpg


Pedals going back in all painted and tried.


http://img.photobucket.com/albums/v3...pst5aqkmcs.jpg


Everything back in. Filled up with 5.1 fluid.. Big thanks to Dan who helped me bleed them...
Bleed everything, pedal started feeling good, when Pete notice some fluid. I didn't spilt any! GReat!


http://img.photobucket.com/albums/v3...psipxpnhpf.jpg


Fluid was leaking out from under the servo! Took the Mc off and it felt dry. But much off been leaking through the seal in to the servo. FFS!
Hour later after a message or two and Nemise has a servo and mc and he was taking it off! As my dad happened to be 15 mins away from it. Big thanks to Ben for that.


Few days later and i had bled all the new fluid out and stripped it all again.
Doing the swap. am annoyed i should of painted the servo before fitting... But was running out of time.


http://img.photobucket.com/albums/v3...psxdpmgb4h.jpg


Picked up a pressure bleed kit, so i didn't have to bug Dan to help me after work. Got it all bled up and a great feeling pedal.


Due to where the servo is, the pipe would of been a bit of a rubbish angle. So popped to see my good friend in the hydo place with the servo pipe fitting, who found me one of these. Founds some "new" (read old stock from my work) servo pipe i had in stock.


http://img.photobucket.com/albums/v3...ps3w66ovan.jpg


Made the hose up. Connect up my wiring, new end on the main power and 2 on the smaller wires.


http://img.photobucket.com/albums/v3...psoj6v6l3v.jpg


All heat shunk and fitted.


http://img.photobucket.com/albums/v3...ps0pvapxxh.jpg


Was never happy with this white plastic on the clutch cable.


http://img.photobucket.com/albums/v3...pscbhtsbte.jpg


So painted it black. Looks much better with the chromed bracket it sits in.


http://img.photobucket.com/albums/v3...ps3k2p0cfj.jpg




Car started first time. That was good.
So now we're at Sat morning before PVS.


Huge thanks to Dan here.
I'd be struggling to get the steering column to fit right. Finally remove the "new" column i'd fitted, found of a mk1 column is shorter than a mk2!!
So had to refit my column, remember the state of it?
Dan sat and hand filed it! Am still gonna replace it tho.
Before...


http://img.photobucket.com/albums/v3...psovzyyrmg.jpg


After,


http://img.photobucket.com/albums/v3...psezloqpfd.jpg


http://img.photobucket.com/albums/v3...psogyl2hvt.jpg


While he was Legendary it up.
I had to cut up my scuttle cover, as the MC and fluid tanks sit alot higher. It's not finished dont worry. This was a run out of time finish.


http://img.photobucket.com/albums/v3...pshobm8luc.jpg


And i fitted the temp panel i had made up to cover the holes in the bulk head... Till i can weld them up.


http://img.photobucket.com/albums/v3...psukowjdd4.jpg

Leads up up to now. Few things to note.

Pedal is fantastic, braking is 50 times better than the Nova braking.
But the pedal needs lowering. As you really have to lift your foot up off the power to brake, which i'm not happy with, but is semi easy fix.