CG's rebuild thread. PROJECT COMPLETE

OK. Dunno where the motivation came from but Ive just returned from the garage.
After all the rain & shizzle we've had here in Somerset recently, the hole I bored in the battery tray was letting water into the cabin & suffice to say the drivers footwell was a bit damp. So I want the servo bolted down once & for all. I had to remove the rear battery rest, which left behind a bunch of holes from the spot welds. Anyone that knows about Novas will be aware that the battery tray is above the drivers feet. Any holes here will give you damp jeans & probably a wet fuse box, FORD Orion stylee.
http://i30.photobucket.com/albums/c3...rogress031.jpg
So spot weld holes sealed up with some seam sealer..
http://i30.photobucket.com/albums/c3...rogress033.jpg
And Ive also had some slight surface rust from where the battery has moved in the past & rubbed the paint. This has been on the car since I had it 8 yrs ago. Its never got worse or bothered me, but rust does have a habit of eating through metal & making holes, so again for the sake of dry jeans & sound electrics Ive rubbed it back & etch primed it.
http://i30.photobucket.com/albums/c3...rogress034.jpg
Tonights work in its entirety. LOL
http://i30.photobucket.com/albums/c3...rogress036.jpg
Little tip for 2007. Judging by all the Nova builds, invest heavily in this stuff. Guaranteed return!
http://i30.photobucket.com/albums/c3...rogress032.jpg

Tomorrow I'm going to bolt in the servo, pedal & mounting plate with the sealer ring so its water tight.
Then brake lines, something Ive been stalling on.

OK. Been under the fooker again this weekend. I need it to steer so I can move the car about & begin some work at the rear end (tank etc).

I had to remove the old std manual steering rack. here undoing the rack mounts from under the car (drivers arch)
http://i30.photobucket.com/albums/c3...rogress047.jpg

With the rack off I measured accross the centres of the 'rod ends' so I could set up the PAS rack to the same width just as a reference & to make tracking it up quicker when she's a goer.
http://i30.photobucket.com/albums/c3...rogress049.jpg
http://i30.photobucket.com/albums/c3...rogress050.jpg

getting the old rod ends off was a proper biyatch! Some WD40, bashing with a hammer & heat from a blow torch got em off though (I needed the rod end lock nuts).
http://i30.photobucket.com/albums/c3...rogress050.jpg

Heres the Corsa B PAS rack with new rod ends on
http://i30.photobucket.com/albums/c3...rogress055.jpg
http://i30.photobucket.com/albums/c3...rogress054.jpg

The knuckle on the rack that enters the cabin through the bulkhead is much larger on the PAS rack, no doubt due to the hydraulics within, so the bulkhead has to have the hole enlarged (see previous post) so I had to make a grommet type seal to go around the edge of the rack & bulkhead gap.
My can of WD was about the same dia as the knuckle on the rack, so I used the can as a template to cut a hole in a peice of thick rubber I had.
http://i30.photobucket.com/albums/c3...rogress058.jpg

Heres the grommet on the rack.
http://i30.photobucket.com/albums/c3...rogress059.jpg

Heres the rack being bolted onto the car.
http://i30.photobucket.com/albums/c3...rogress064.jpg

Ive had to work alongside some of my old mans shizzle in the garage. Probably the main reason why my progress is so slow. If he isnt rebuilding old bikes of his own, he's peering over my shoulder & telling me how I ought to be doing something.
http://i30.photobucket.com/albums/c3...rogress061.jpg
Theres another 5 bikes in the way too!

Good to see you on it mate

Very good work will use this thread when i finly get my new car loving it load keep up the great work

dude more gen needed on the rack...

ah u found some inspiration this weekend too! good work my friend.

Simps.

Well done Craig.

Quote:

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Originally Posted by Benn

dude more gen needed on the rack...

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Its a modded Corsa GSi rack from a rally car . Any Corsa B rack will fit a Nova. The one I have is from a Nova rally car though. The track rods have been shortened to match the novas track (width) & the internals had been swapped for 'kwik' items which now has a lock to lock of 2.2 turns, compared to 3.75 turns for a regular Nova jobber. Nice!

I was really lucky to pick up the rack off ebay about a year ago for less than ?40. Ive also got an (almost) brand new 12v Saxo pump. I got that for a pittence aswell, so I'm really chuffed with how much its cost.

All I need is the hydraulic lines making now, which I'm struggling with as my local Pirtek chap is dyslexic (putting it kindly).

Good Stuff !

Turrets look the nads, talking of which, you must have nads the size of basketballs cutting lumps that big out of its ass!lol

keep it up!