Nice work on the car Iain, do you like the car handle with this mod?? with the circuit slicks its a big upgrade. I use Yokohama circuit slicks without LSD and the car sense more diferent.
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Nice work on the car Iain, do you like the car handle with this mod?? with the circuit slicks its a big upgrade. I use Yokohama circuit slicks without LSD and the car sense more diferent.
With the EPAS Zeifer? TBH it went from a mostly standard 1.6 to a fully rebuilt/track prepped 2.0 with EPAS in one swoop so its hard to say exactly what benefits, but the steering is lovely and precise consisting of Corsa B EPAS, manual sensitivity controller, Quaife quick rack together with the Michelin slicks and Quaife ATB.
yes, that is i mean. fantastic car Iain, good work.
I have various upgrades to do to the poor beasty this winter, namely:
Replace the crossmember due to cracking
Fit a ZLET oil pump & pickup
New timing belt, pulleys
New shafts & CVs
Replace clutch due to damage
Check crank bearings as I've noticed some side movement in the crank, looks a little too much
Figured with all this to do it'd be easier doing it on a stand so tonight at 5:30 I started with a complete car, and a few hours later I had this:
http://iainel.co.uk/images/forums/NovaWIP2a/953.JPG
Cosmetic bellhousing damage from clutch letting go:
http://iainel.co.uk/images/forums/NovaWIP2a/954.JPG
http://iainel.co.uk/images/forums/NovaWIP2a/955.JPG
Supposed to be two springs on the cover plate here:
http://iainel.co.uk/images/forums/NovaWIP2a/956.JPG
Engine on stand:
http://iainel.co.uk/images/forums/NovaWIP2a/957.JPG
Engine bay doesn't look bad after all the abuse:
http://iainel.co.uk/images/forums/NovaWIP2a/958.JPG
Or does it, more signs of cracks when you poke a bit closer.... Uh oh. This is by the alternator cut out.
http://iainel.co.uk/images/forums/NovaWIP2a/959.JPG
Additional plan may be strengthening kit, extra welding and an engine bay respray too then...
Good work, now its time to refresh the little nova:thumb:
Oh dear, time to add a load of meat to that area!Quote:
Originally Posted by Iain
Loving your work though, its held up well
It seems everywhere I've added metal/weld/strength it's cracked around it. For example the crossmember. I do worry just adding more will move the problem elsewhere.
In two minds whether I want to put in a beefy crossmember or just a standard replacement with this in mind. Although if custom I can make it lower down and move back to poly bushed tiebar brackets which should batter the crossmember less than the lowered rosejointed items I have.
Not necessarily just welding more metal in with just the welder but adding a steel plate to act as a load spreader?Quote:
Originally Posted by Iain
Bell housing is just surface and will be fine. What's the clutch friction plate like, any damage as seems to have loads of meat left which is a shame?
That stand and crane look spot on and the loan price was only a lifetime supply of jelly sweets for me :)
why didn't he use his winch lol
Wench was that? (sorry Hayley, couldn't resist)Quote:
Originally Posted by turbojolt
Hayley is a wench.........I spell how I talk so its all retarded lol
Nice work, crack doesn't look too bad, beef it up with some wider metal to spread out the stresses. That will spread out the force and be stronger..
Think if i was removing the cross member i'd made a better stronger lower one. Then you could get a bigger custom rad in there (as you've had temp issues) And it will be much stronger too.
Zlet oil pump it a good upgrade, i get much much better pressures.
Blimey your price has gone up since I borrowed them.Quote:
Originally Posted by Harvey
Their claim to fame was they lifted and supported my C36GET.
http://i71.photobucket.com/albums/i1...e/DSCF1577.jpg
http://i71.photobucket.com/albums/i1...e/DSCF1619.jpg
Water temp has never been an issue just oil temps.Quote:
Originally Posted by Benn
Yeah I'll fix that crack no worries. I plan to put a new cross member in lower than the original so I can run original tiebar brackets instead of the rose jointed ones to reduce stress on the shell. Currently thinking CDS with boxed ends for the tie bars.
That explains why the crane looks a bit banana shaped Keif (Only joking Harvey it's fine honest)
OK on with the engine stripdown, glad I put some effort into the freshen up after seeing the state of the bearings.
Crank out, measured up and all within tolerance:
http://iainel.co.uk/images/forums/NovaWIP2a/960.JPG
Engine looking bare:
http://iainel.co.uk/images/forums/NovaWIP2a/961.JPG
Shells looking worse for wear lol
http://iainel.co.uk/images/forums/NovaWIP2a/962.JPG
http://iainel.co.uk/images/forums/NovaWIP2a/963.JPG
Old oil pump out that's being replaced due to pressure dropping issues:
http://iainel.co.uk/images/forums/NovaWIP2a/964.JPG
AutoVaux delivery, big thanks to them for sorting that lot out quickly and well priced:
http://iainel.co.uk/images/forums/NovaWIP2a/965.JPG
New +.25 bearings installed and lubricated:
http://iainel.co.uk/images/forums/NovaWIP2a/966.JPG
Crank installed, spins nicely and endfloat all within tolerance:
http://iainel.co.uk/images/forums/NovaWIP2a/967.JPG
Mmmm new Z20LEH oil pump internals:
http://iainel.co.uk/images/forums/NovaWIP2a/968.JPG
The crank seal just needs removing and fitting with an XE one due to ID size differences:
http://iainel.co.uk/images/forums/NovaWIP2a/969.JPG
Installed with steel gasket:
http://iainel.co.uk/images/forums/NovaWIP2a/970.JPG
Now due to the difference in pickup shape, you can't use a standard pickup pipe so it needs to be custom made. Got this nicely custom made thing from Germany (TBW Automotive)
http://iainel.co.uk/images/forums/NovaWIP2a/971.JPG
Bit of fun trying to fit all these 'custom' parts.... It was nowhere near clearing the baffled sump as it runs down the middle:
http://iainel.co.uk/images/forums/NovaWIP2a/972.JPG
So this had to get chopped, ground down and hammered in slightly unfortunately:
http://iainel.co.uk/images/forums/NovaWIP2a/973.JPG
Sump got modified to take M8 bolts as the ZLEH pump uses M8s:
http://iainel.co.uk/images/forums/NovaWIP2a/974.JPG
As did the sump baffle, just needed the inserts knocking out
http://iainel.co.uk/images/forums/NovaWIP2a/975.JPG
All fitted up:
http://iainel.co.uk/images/forums/NovaWIP2a/976.JPG
Then sump on, all sealed up.... New SKF pulleys, belt and all bolted back together and timed up:
http://iainel.co.uk/images/forums/NovaWIP2a/977.JPG
Engine will get it's new inlet system when it's installed in the car :)
FAntastic work, you cracked it all thought quick too.
http://iainel.co.uk/images/forums/NovaWIP2a/975.JPG
Ref this pic, did you fit the gasket on the end of the pick up pipe?
How come youre using oversized bearing shells? had crank ground before??
Did you find the cause of low oil pressure?
Took a while to gather all the parts but it all came together quick. Yeah rubber oval gasket on the pick up Benn.
Yes Andy crank got reground on first build. Measures up fine based on adding 0.25 to the measurements to check within tolerance.
I think and hope the pressure issues were the old XE oil pump so fingers crossed the gauges look healthy now.
Nice one mate, some nice new parts, this will be awesome on tbs, can't wait to see it back and running, if I get chance be nice to go out in it..
Nice work Iain ,did you sort an ECU out as I am thinking of upgrading my MBE
Yeah sounds good Scott we'll go for a blast, look forward to seeing what the throttle bodies give, but also looking to some more space/less cluttcher in the engine bay!
Cheers Toymex, I haven't sorted an ECU/loom out yet all the mappers I've talked to seem to recommend Omex though so wouldn't mind finding a second hand Omex 600 at a reasonable price.
After some useful pics of people replacing their crossmembers on here, I've butchered my poor Nova ready for it's new one. lol
Engine bay and tiebar brackets braced up with some spare steel tube I've got kicking about:
http://iainel.co.uk/images/forums/NovaWIP2a/978.JPG
http://iainel.co.uk/images/forums/NovaWIP2a/979.JPG
Ended up ripping it apart to remove due to space issues next to the tiebars:
http://iainel.co.uk/images/forums/NovaWIP2a/980.JPG
Then it fell off:
http://iainel.co.uk/images/forums/NovaWIP2a/981.JPG
Good job I'm removing it tbh, this nice thick plate I welded over some rot when I built it:
http://iainel.co.uk/images/forums/NovaWIP2a/982.JPG
Is cracked all underneath it:
http://iainel.co.uk/images/forums/NovaWIP2a/983.JPG
Equally cracking on the other side lol
http://iainel.co.uk/images/forums/NovaWIP2a/984.JPG
I plan to mount the crossmember lower to suit the lowered tiebar bracket position,, which is unfortunate as removing it gives you this nice little square to weld into. You can see the different levels here:
http://iainel.co.uk/images/forums/NovaWIP2a/985.JPG
Quick mock up of what I'm thinking of doing, 50x50mm box section to bolt the tiebar bracket onto, 25cm either side, joined between the chassis legs with a run of CDS tube:
http://iainel.co.uk/images/forums/NovaWIP2a/986.JPG
It naturally wants to sit the box section about 5-6mm in front of the tiebar bracket, which I might go with in order to gain some castor. I can always space it out on the tiebar before the bracket if the lower arm bushes can't cope with it:
http://iainel.co.uk/images/forums/NovaWIP2a/987.JPG
More updates when I've done some more :)
Nice, fair play to going balls out on it!
its taken him two days of man up pills to start cutting it lol
Are you sure a couple of tacks per bracket is enough for holding them in place?
Like it.
They seem quite solid BRoadGhost. Bolted them in place, tacked and removed the bolts and given them a good wiggle and they've not moved. Got various measurements in every direction too just in case.
they don't move anyway
POST 1 OF 6
Lots of pictures, finished my crossmember now.
50x50 3mm box section used to mount the tiebars against, I cut these to size for either end and drilled to suit:
http://iainel.co.uk/images/forums/NovaWIP2a/988.JPG
This nut was welded inside the box section to create a captive nut, the other holes were just drilled through on the pillar drill:
http://iainel.co.uk/images/forums/NovaWIP2a/989.JPG
4 washers were used to space the square section forwards from the original tiebar location:
http://iainel.co.uk/images/forums/NovaWIP2a/990.JPG
It was all levelled up and tacked together:
http://iainel.co.uk/images/forums/NovaWIP2a/991.JPG
Then fully stitch welded top and bottom:
http://iainel.co.uk/images/forums/NovaWIP2a/992.JPG
Getting there...
http://iainel.co.uk/images/forums/NovaWIP2a/993.JPG
The chosen crossmember position was 4.6mm further forward than standard using the 4 washers...
http://iainel.co.uk/images/forums/NovaWIP2a/994.JPG
And 18.5mm lower than standard, by positioning it on the tie bar brackets without the spacers in place:
http://iainel.co.uk/images/forums/NovaWIP2a/995.JPG
POST 2 OF 6
So time to make it a 'proper crossmember', start with it stitched:
http://iainel.co.uk/images/forums/NovaWIP2a/996.JPG
Cut plate to box it together:
http://iainel.co.uk/images/forums/NovaWIP2a/997.JPG
All tacked in place:
http://iainel.co.uk/images/forums/NovaWIP2a/998.JPG
And welded on, together with an end cap:
http://iainel.co.uk/images/forums/NovaWIP2a/999.JPG
Smoothed off:
http://iainel.co.uk/images/forums/NovaWIP2b/001.JPG
Attached to the car with lowering blocks made of the same 50mm box section:
http://iainel.co.uk/images/forums/NovaWIP2b/002.JPG
This meant the bracing could then come off:
http://iainel.co.uk/images/forums/NovaWIP2b/003.JPG
POST 3 OF 6
Scary moment, trying the suspension on to check I've not messed up too badly:
http://iainel.co.uk/images/forums/NovaWIP2b/004.JPG
I did plan to use the OE tiebar brackets but I didn't like the angle the bush sat on the front, so I have decided to use the spherical bearing ones. Unfortunately due to this line of weld, I can't fit them on my new crossmember:
http://iainel.co.uk/images/forums/NovaWIP2b/005.JPG
So I'll have to use one of the ally spacers, bringing my tiebar down another 6mm or so:
http://iainel.co.uk/images/forums/NovaWIP2b/006.JPG
While prepping for the bracing I found some rot, eek:
http://iainel.co.uk/images/forums/NovaWIP2b/007.JPG
Chopped out:
http://iainel.co.uk/images/forums/NovaWIP2b/008.JPG
Making up some repair bits:
http://iainel.co.uk/images/forums/NovaWIP2b/009.JPG
All strong again:
http://iainel.co.uk/images/forums/NovaWIP2b/010.JPG
POST 4 OF 6
Ends of the crossmember then boxed off:
http://iainel.co.uk/images/forums/NovaWIP2b/011.JPG
And two end caps made from sheet steel:
http://iainel.co.uk/images/forums/NovaWIP2b/012.JPG
Weldy weldy:
http://iainel.co.uk/images/forums/NovaWIP2b/013.JPG
Other side got the same treatment:
http://iainel.co.uk/images/forums/NovaWIP2b/014.JPG
Then created boxed sections on both sides:
http://iainel.co.uk/images/forums/NovaWIP2b/015.JPG
http://iainel.co.uk/images/forums/NovaWIP2b/016.JPG
Inner chassis leg plates made up:
http://iainel.co.uk/images/forums/NovaWIP2b/017.JPG
More weldy weldy:
http://iainel.co.uk/images/forums/NovaWIP2b/018.JPG
Then flushed them off with the flapdisc:
http://iainel.co.uk/images/forums/NovaWIP2b/019.JPG
And finally capped off the fronts, with holes for water drainage so it doesn't hold water:
http://iainel.co.uk/images/forums/NovaWIP2b/020.JPG
POST 5 OF 6
Legs for the radiator to sit on, moved it towards the middle of the car a bit and slightly forward for more exhaust clearance:
http://iainel.co.uk/images/forums/NovaWIP2b/021.JPG
Plenty of bumper clearance:
http://iainel.co.uk/images/forums/NovaWIP2b/022.JPG
I plan to use the new crossmember for jacking up the front, so I've made the front bumper easier to remove by bolting on some threaded sections to the original bumper brackets (just a mock up at the mo):
http://iainel.co.uk/images/forums/NovaWIP2b/023.JPG
Now it can bolt on through the front with 2 M12 bolts, all lined up properly:
http://iainel.co.uk/images/forums/NovaWIP2b/024.JPG
POST 6 OF 6
Couple of pics of the finished crossmember, going to repaint the chassis legs and stonechip the crossmember black:
http://iainel.co.uk/images/forums/NovaWIP2b/025.JPG
http://iainel.co.uk/images/forums/NovaWIP2b/026.JPG
http://iainel.co.uk/images/forums/NovaWIP2b/027.JPG
http://iainel.co.uk/images/forums/NovaWIP2b/028.JPG
And repaired the crack I showed earlier in the thread:
http://iainel.co.uk/images/forums/NovaWIP2b/029.JPG
Nice fabrication there :)
epic. if this cracks its time to move on lol
Top work, can see your efforts and detailed pics innovating a few novas on here.
It's harder to weld against gravity huh? ;0 Should be plently strong-a-pull.
Simply amazing Iain, good work:thumb: