Iain's 20XE Trackday Nova

PART 3/3

Something I've had a for a while and just got round to fitting, I wanted some window nets so I can crack my windows open on trackdays. The proper way to fit these is round the cage, but my massive seats don't allow that, so I've welded some bracketry to the top of the door frame:


http://iainel.co.uk/images/forums/NovaWIP2b/138.JPG


http://iainel.co.uk/images/forums/NovaWIP2b/139.JPG


This allows a top rail to be clipped in:


http://iainel.co.uk/images/forums/NovaWIP2b/140.JPG


Window net with top and bottom rail:


http://iainel.co.uk/images/forums/NovaWIP2b/141.JPG


It was slightly too tall to fit on the door so I hired a Hayley to stitch the bottom hoops to reduce the total height (on pic above):


http://iainel.co.uk/images/forums/NovaWIP2b/142.JPG


Rivnuts on bottom of door frame:


http://iainel.co.uk/images/forums/NovaWIP2b/143.JPG


Window net in place:


http://iainel.co.uk/images/forums/NovaWIP2b/144.JPG


Drivers side done too:


http://iainel.co.uk/images/forums/NovaWIP2b/145.JPG


http://iainel.co.uk/images/forums/NovaWIP2b/146.JPG


Nice big red button visible on passenger side for quick removal:


http://iainel.co.uk/images/forums/NovaWIP2b/147.JPG


All done:


http://iainel.co.uk/images/forums/NovaWIP2b/148.JPG

Erm I might need to double check this on my images (not on right computer atm) but those shaft ends look to come to too sharp a point; this would explain your play woes.

There's still a tiny bit of movement on the splines on the new shafts, however I tried an OE CV on an OE Vauxhall shaft and they had a similar amount of movement. Hoping the hardening on these stops them wearing down and becoming extremely sloppy like the last ones.

Hopefully the shafts do the job and don't snap/wear. Broadghost, the ones I made are an exact (within .001") of a set of equal length shafts I had.

Shafts are shiney, i approve. Like the window nets too.

Some niggly jobs sorted now, I can finally use the car.

Unfortunately didn't make it to Billing as diagnosed a fairly bad gearbox fault, so cracked on with fixing it.

Whilst the box is off, I ran the engine up on 1 mount and 2 axle stands:

http://iainel.co.uk/images/forums/NovaWIP2b/149.JPG

Oil leaks, sponsored by Imperial Leather lol Talcum powder clearly showed the problem leak, the end cap! You can see it on the right join here:

http://iainel.co.uk/images/forums/NovaWIP2b/150.JPG

So sump, pickup, gasket etc off, then end cap off and resealed properly with RTV:

http://iainel.co.uk/images/forums/NovaWIP2b/151.JPG

Now onto the good stuff, the gearbox. It had been having really bad feedback through the selector turret and up the stick for a while, and something was amiss. I ran it up on axle stands without the selector turret on and noticed a hell of a lot of movement through the output shaft, so unfortunately it had to be stripped.

So box off:

http://iainel.co.uk/images/forums/NovaWIP2b/152.JPG

End cap and fifth coming off:

http://iainel.co.uk/images/forums/NovaWIP2b/153.JPG

Cluster out:

http://iainel.co.uk/images/forums/NovaWIP2b/154.JPG

Cluster stripped, which involved removing all the selector arms, circlips, etc, got a pile of bits at this point lol

http://iainel.co.uk/images/forums/NovaWIP2b/155.JPG

The culprit, the large circlip holding the output shaft into the end plate wasn't actually seated at all, so it was just bouncing between the end casing and the gears and the other shaft gears, eek. The circlip is damaged as is the needle bearing spacer pictured here. The spacer was actually fitted the wrong way round which meant the circlip would never seat properly...

http://iainel.co.uk/images/forums/NovaWIP2b/156.JPG

Luckily I have a spare cluster (well, 2), so I've used the end casing, circlip, spacer and needle bearing from the spare cluster, and re-used both shafts and casing from the current box. Bit sparse on pictures, but it's all built up again all clean:

http://iainel.co.uk/images/forums/NovaWIP2b/157.JPG

Refitted an there's a tiny bit of movement but very happy with it now. No more leak from the gearbox end, so one happy Iain.

Thanks to Stuart for the explanation for stripping the box and Harvey for lending a hand with the sump sealing.

Top work old chum!!

It was very satisfying hitting your shaft very hard.

Just glad the box is sorted, strange it never did it when I had it fitted but I do drive like Miss Daisy. I'll get my engine drip sorted one day.

It's not a real Vauxhall if it doesn't drip oil Harvey!!!

I've only fixed all the bloody leaks took it out for a few hours last night and the garage floor is bone dry today!

Quote:

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Originally Posted by Iain

I've only fixed all the bloody leaks took it out for a few hours last night and the garage floor is bone dry today!

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I give it a couple of days and something will be leaking again lol lol lol

#vauxhall life

Quote:

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Originally Posted by Iain

I've only fixed all the bloody leaks took it out for a few hours last night and the garage floor is bone dry today!

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This is a deceptive facade, it'll leak, they always do!!!!

Christ you havent hung about. Good work.

Bit of prep done over the last few weeks for Cadwell. Swapped out the TX Autosport radiator for a standard Valeo item. Strip down:

http://iainel.co.uk/images/forums/NovaWIP2b/158.JPG

New one installed:

http://iainel.co.uk/images/forums/NovaWIP2b/159.JPG

Short (standard) F20 fifth installed:

http://iainel.co.uk/images/forums/NovaWIP2b/160.JPG

Front ride height raised, slicks trial fitted, tracked up 1mm toe out:

http://iainel.co.uk/images/forums/NovaWIP2b/161.JPG

Window nets bolted into place:

http://iainel.co.uk/images/forums/NovaWIP2b/162.JPG

Careful measuring of window:

http://iainel.co.uk/images/forums/NovaWIP2b/163.JPG

Rear ventilation holes drilled to aid airflow out the car since I'll be driving with my windows open:

http://iainel.co.uk/images/forums/NovaWIP2b/164.JPG

Rain was forecast, so had Hayley paint up my wet rims:

http://iainel.co.uk/images/forums/NovaWIP2b/165.JPG

Cadwell today with a team of sleep deprived grumpy people lol

Team mascot pigeon:

http://iainel.co.uk/images/forums/NovaWIP2b/166.JPG

Did some fairly poor and inconsistent laps struggling with the track complexity, then on a lap out with House this happened:

https://www.youtube.com/watch?v=H8D1...ature=youtu.be

Uh oh, so after a red flag and tow off the track this is the failure:

http://iainel.co.uk/images/forums/NovaWIP2b/167.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/168.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/169.JPG

Brand new GKN inner CV joint, now fit for scrap, boooo. Not to worry though! I had chucked my old welded shafts in the boot, so fitted the replacement with the aid of a new castle nut from Harveys spares, and went back out after lunch to carry on! Happy days.

Pic of the trio:

http://iainel.co.uk/images/forums/NovaWIP2b/170.JPG

And a small mishap on the last session lol

https://www.youtube.com/watch?v=9L7XFv2V3N8&feature=youtu.be

Just sorting out footage of my best clear laps :)

The best 2 lines of the day........

"That doesn't sound good?!?!"

"I broke it"

Why have you got a 5cm diameter steering wheel?

Always had it, had no real reason to change it to a bigger one to be honest?

Couple of clear laps on video.

https://www.youtube.com/watch?v=yeFizRIGZDI&feature=youtu.be


Car handles really well, slicks still have some life left in them, brakes are sharp on DS3000s and oil temps and pressure stay good. Open windows up front makes for a nice cool drive on hot days, so I'm not sure what I'm going to do with the thing to improve it now!

Nice bit of driving Iain. Handling looks very good! :thumb:

Quote:

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Originally Posted by Edd

Why have you got a 5cm diameter steering wheel?

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Bigger steering wheel also means that when turning in to a corner or correcting over steer or under steer mid corner you hands have to go further to apply lock or opposite lock.

Yes, the steering is harder to turn but you don't have to turn the wheel as far, also I've found on track that heavier steering is a plus as it feels more direct and engaged with the surface. Just my take on it.

No steering is hard with EPAS lol

Quote:

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Originally Posted by Iain

No steering is hard with EPAS lol

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Only girls use EPAS.

So the car seems pretty complete now then Iain?
any other plans for it? Seems to go well and handle nicely on track.
Can I ask why you swapped the tx radiator for a standard one? Looking at getting a tx one for mine. A few people seem to have problems with them tho.

Yeah bizarrely nothing to really improve on, other than the broken CV joint. Probably find some other track/race inspired tweaks but nothing major.

I had my TX one welded once, and noticed when up to temperature it 'steamed' slightly from the top. Held pressure mostly and ran cool enough, just wasn't properly sealed. I do regret having to go back to a standard radiator, the fins are too delicate and get damaged easily. In my fact my Valeo one picked up a whole load of damage just fitting it. lol

Really like your car and the work you have done. This thread makes for interesting reading. I think i may go towards this route of mods once i get bored with how mine is. I have already starting drafting a wish list for next winter lol

Awesome! Awesome! Awesome! :thumb: Car shifts, sounds epic, and looks the part. Quality bit of driving, too ... You look familiar with getting round Cadwell Park lol.

Quote:

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Originally Posted by House1983

Only girls use EPAS.

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We are all female as heart....moobs :d

Quote:

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Originally Posted by Harvey

We are all female as heart....moobs :d

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To be fair Harv the girl dealt quite well with his mullered CV joint, I was expecting tears and toys being thrown out the pram!!!!

Thanks chaps, glad you like it.

Quote:

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Originally Posted by House1983

To be fair Harv the girl dealt quite well with his mullered CV joint, I was expecting tears and toys being thrown out the pram!!!!

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Getting used to this kind of thing happening lol

Love all the vids. Love the first video, the cv die and the "Oh crap" feeling.. I know that one all to well. Spin was handled well too.
Holding speed and the track very well, impressive driving as always.

Quote:

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Originally Posted by Iain

Thanks chaps, glad you like it.



Getting used to this kind of thing happening lol

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mainly cos you drive it like you stole it!!

Love the "I broke it" lol
Last video is brilliant, it's flying dude!..

Quote:

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Originally Posted by scott.parker

Love the "I broke it" lol
Last video is brilliant, it's flying dude!..

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It was flying...... Flying over the kerb on the inside of the mountain, that's what blew the CV as we landed!! That and my 107kg in the passenger seat!!!!!

Theres no such thing as finished lol

Impressive btw, got a pretty much perfect track weapon!
Good to see you actually give it some boot as well and not treat it nicely.

Adam was correct (for once), found something else to tinker with.

Good guide with info in on the SBD website with bolt sizes: http://www.sbdev.co.uk/Info_sheets/A...20brackets.pdf

Denso 40a compact alternator vs standard XE alt

http://iainel.co.uk/images/forums/NovaWIP2b/171.JPG

Vauxhall bracket part number for anyone who wants to know. I used a 9.5mm spacer instead of SBD's suggested 14.5mm spacer which has placed the alternator in the right place

http://iainel.co.uk/images/forums/NovaWIP2b/172.JPG

Alternator part number, marking on the right is the wiring plug instructions too:
S = sense, a perm 12v source away from the alternator, which I haven't bothered connecting,
IG = Ignition live
L = Light

http://iainel.co.uk/images/forums/NovaWIP2b/173.JPG

Adjuster bracket needed lengthening to suit it further down

http://iainel.co.uk/images/forums/NovaWIP2b/174.JPG

Alt even came with a lovely splashproof crimped plug

http://iainel.co.uk/images/forums/NovaWIP2b/175.JPG

Alternator bracket in place (the large stud on the top is the perm +ve connection)

http://iainel.co.uk/images/forums/NovaWIP2b/176.JPG

Teeny weeny

http://iainel.co.uk/images/forums/NovaWIP2b/177.JPG

Belt is a temporary one I found that fits, it's 10x875 V velt.


I've also put the radiator fan on a switch inside the car and tidied up loads of wiring, yipee.


Snetterton on 21st, so car's pretty much ready for that.

Great little alternators, I found mine in an Axiam thing at a scrappy for 20 quid! And while there a liberated a mk3 Astra mount too

Happy days Mazz, well chuffed seems to charge fine even with most things on.

I've done this all with brand new parts but on a budget with bargains over the last few months... Alternator was about £40, bracket £8, then just misc rosejoints and spacers and stuff!

I'm sure the same on sbd site is over £200!

Tasty!! I'm guessing the alternator doesn't move left to right at all? I noticed when using a rose joint tensioner that the alternator could wiggle about a few mm, it wasn't rock solid like it is on the standard mount.