My Nova Rebuild Thread...

Havent done one so here it is!

Started life as a 1.4 SRi. Used to owned my a Novaload user, Freak. I kept the car pretty much as i bought it, fitted a backbox and meshed the front grill, painted the alloys. Used it in this state for a while, did a few sessions round Castle Combe, great fun!! I then got bored so took it off the road with the intention of building a C20XE to put in it and got abit carried away...

http://img.photobucket.com/albums/v3.../novasri01.jpg

http://img.photobucket.com/albums/v3.../nova01BIG.jpg

How it looked when i bought it.

http://img.photobucket.com/albums/v3...ova/TheCar.jpg

I had the wheels painted, added some side reps and that was about it.

http://img.photobucket.com/albums/v3...nginebay01.jpg

The strip down starts!! Out with the old C14SE (which was a bloody good engine, made my mate in his saxo vtr look silly. Not hard to do i hear you say!)

http://img.photobucket.com/albums/v3...ppedbayF-2.jpg

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

http://img.photobucket.com/albums/v3...ippedint01.jpg

http://img.photobucket.com/albums/v3...int01007-1.jpg

There was alot of rust/rot within my engine bay, so first port of call was to remove the front panel and crossmember (what fun!!) and replace it. I also cut out the rust from the inner wings and pplated them up.

http://img.photobucket.com/albums/v3...anelold005.jpg

front panel off.

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

Rot on the inner wings. This was all cut out and plated.

http://img.photobucket.com/albums/v3...ept2005002.jpg

I constructed a chassis stand, so as the car could be moved. I had removed all running gear.

http://img.photobucket.com/albums/v3...el001007-1.jpg

Front crossmember removed. I braced between the engine mounts and fitted a strut brace. This was more a precaution than anything.

http://img.photobucket.com/albums/v3...anel001008.jpg

I then set about grinding back all surfaces that needed welding. This included areas for the Harry Hockley plate kit.

http://img.photobucket.com/albums/v3...anel002007.jpg

http://img.photobucket.com/albums/v3...anel002006.jpg

http://img.photobucket.com/albums/v3...el002005-1.jpg

http://img.photobucket.com/albums/v3...Nova/Nova3.jpg

My good mate Stu doing the welding. He works in a bodyshop, so his expertise were welcomed at this stage of the rebuild.

The bulkhead was also seam welded.

http://img.photobucket.com/albums/v3...anel001006.jpg

http://img.photobucket.com/albums/v3...yprimer006.jpg

http://img.photobucket.com/albums/v3...yprimer007.jpg

Once the cross member was welded and the engine bay was seam welded, i gave it a ll a good coat of primer. This rebuild was done in stages so didnt want rust to set in a ruin all my (our!!) hardwork.

http://img.photobucket.com/albums/v3...a/Nova0024.jpg

http://img.photobucket.com/albums/v3...a0025-Copy.jpg

The front panel was then fitted and a trial fitment of the wings. They turned out to be crap! Pattern wings!

Some nice touches. I always liked breeze blue SR's.

I look forward to seeing it unfold.

I then bought myself a compressor and painted the engine bay to colour code it all!

http://img.photobucket.com/albums/v3...Nova0041-1.jpg

http://img.photobucket.com/albums/v3...a/Nova0042.jpg

Nothing missed out on a lick of paint. The upper members, inner wings, wheel housings, the lot!

http://img.photobucket.com/albums/v3...va/Nova003.jpg

The underneath of the car didnt go un-noticed! It probably will when it hits the road though:( Will have to construct some special mirrors!

http://img.photobucket.com/albums/v3...pedrear005.jpg

http://img.photobucket.com/albums/v3...pedrear007.jpg

Firstly is attached a wire brush attachment to my angle grinder a cleaned it all up. Wasnt fussed about the removal of the underseal.

All fixtures and fittings were removed, then it all got a coat of primer. What a labour of love!

http://img.photobucket.com/albums/v3...primer01-1.jpg

http://img.photobucket.com/albums/v3...primer03-1.jpg

http://img.photobucket.com/albums/v3...primer02-1.jpg

Then i painted it all to match the rest!

http://img.photobucket.com/albums/v3...paint01006.jpg

http://img.photobucket.com/albums/v3...earbeam005.jpg

http://img.photobucket.com/albums/v3...earbeam006.jpg

Couldnt just slap my rusty rear beam back on so...

http://img.photobucket.com/albums/v3...paint01001.jpg

http://img.photobucket.com/albums/v3...paint01003.jpg

http://img.photobucket.com/albums/v3...rbeam008-1.jpg

...and some repainted shocks and springs.

http://img.photobucket.com/albums/v3...a/Nova0049.jpg

http://img.photobucket.com/albums/v3...a/Nova0047.jpg

mmmm, freshly painted lovliness!!

I then set about getting the car ready for the paint shop.

http://img.photobucket.com/albums/v3...a/Nova0044.jpg

http://img.photobucket.com/albums/v3...a/Nova0043.jpg

http://img.photobucket.com/albums/v3...a/Nova0022.jpg

Took out all the windows, windscreen (which cracked!) lights etc. Borrowed a mates electric DA and went for it!! Took no time at all to rub down. Will give it a final DA before it goes for paint.

Stupid really but looking back throughthis thread, doesnt look as thoughi have done an awful lot in the last 3, nearly 4 years!!! Trouble is i have never "just got on with it"!! Not long after i started the rebuild me and my g/f moved in together and that took up all my spare time and of couse, money:roll: .

I also got slightly sidetracked with my daily runners! Firstly had a Renault 19 16v, tidied that up swapped it for an E30 BMW 325, sold that bought a Cav GSi, tidied that up then sold it bought a Cally 16v off Ernie, tidied that up sold it.... you get the idea! Trouble is any money or time i had got took up with this! I then decided to buy a house with my g/f (even less money to do the Nova!) and do my bike test, something i had wanted to do for years. Which kind of brings us up to date! Passed my test august last year, was making some progress on the Nova. This summer was looking to get it painted and maybe engine in. But it was not to be...

Firstly my mum and dads garage caught fire, the Nova and all my tools, parts etc were in there not to mention my dads tools. This is what i was presented with...

http://img.photobucket.com/albums/v3...aragefire1.jpg

Luckily (well not really!) the fire was mainly in the roof. The car escaped bar some smoke damage. Trouble is all my interior, lights, engine parts etc were in the roof and subseqently got either melted of smoke damaged:( I know from the pic it doesnt look bad but it was. The whole roof had to be replaced as all the joists wre charcoal, what the fire didnt destroy the smoke did! My bumpers were just a plastic shape! My doorcards were, well, charcoal.

...But thanks to Lee H off here i managed to replace the majority of lost parts. So i intended to commence the rebuild throughout the summer, but...

I crashed my bike in June this year. Seriously! I hit a tractor whilst overtaking a car and the tractor. It turned right and i connected with it! A 2 week stay in hospital and multiple injuries (of which im still off work now!) hence why the rebuild will have to wait til after xmas at least:(

But im going to get it finished. I want to "do" the Nurburgring before im 30! I was 26 last week so ive got time!!

Sorry for blabbing, on ill get back to posting pics up!.....

http://img.photobucket.com/albums/v3...va/myC20XE.jpg

I bought a mates Astra GTE16v for not alot of money. I kept the engine and gearbox plus a few other bits and broke the rest for spares.

I then set about stripping the engine, ready for a rebuild...

http://img.photobucket.com/albums/v3...own-washed.jpg

http://img.photobucket.com/albums/v3...ripdown004.jpg

http://img.photobucket.com/albums/v3...eanblock02.jpg

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

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

Was good fun but turned out to be a pointless excercise as there was a nasty lip around the top of the block liners. I would have to either have it re sleeved or over bored which would cost money. Money i didnt really have. Luckily, Chip form MIG, had a short engine for sale so i snapped it up! I then bought a coscast head of Bert, had this breathed on by Gary from MIG, and my engine was coming together.

http://img.photobucket.com/albums/v3...agepics002.jpg

The "workshop" i.e my parents garage!

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

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

My interior. This lived after the fire as i left it in the car. Front seats were done when i bought the car, my mum finished the rear seats. I now have a GSi dash and door cards (cheers Lee H) to complete my interior.

Not many up to date pics as not alot has been done as of late. Will update soon as im up and about.

This was the Astra i broke up...

http://img.photobucket.com/albums/v3...r/TheDonor.jpg

http://img.photobucket.com/albums/v3...tripped001.jpg

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

Quote:

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Originally Posted by craig green

Some nice touches. I always liked breeze blue SR's.

I look forward to seeing it unfold.

---

Cheers Craig. I too like breeze blue SRi's;) . This is my second one!

looking good mate awsome project
:thumb:

Novas looking good mate - Good attention to detail :)

Keep up the good work!

Glad to see your still getting on with it fella.

Got a PM from Freak over on MIG, which was abit of a shock, then Breeny (i bought my s/s exhaust off him when he broke his Nova a while back) aswell who has got some old before pics of the Nova. When i get them ill post them up!

Didnt think those guys came on MIG/PNG anymore!

;)

I usually just pop on from time to time but I'm off work ill at the mo so I've been coming on quite a bit.

Keep the updates coming! :)

Not much done lately. Just been aquiring parts. :D

Set of rear pop out windows
Blue XE Nova Samco hoses
Blue alloy single v bottom pulley
Polished rocker cover
Alloy header tank
Cool running stat

My first bit of work will be to remove the spare wheel well and weld it up with my new mig welder. Not before testing my skills on scrap first! I also need to go up north to Huddersfield and collect my dash, wings, headlights, etc (cheers Lee H) after my stuff got burnt in the fire:( ! Then finish the engine off so it can be dropped in after paint.

I can then complete the prep for paint then off to the bodyshop!!:D

All this will probably be december time, still not back to work or 100% fitness after my bike accident.:(

Looking good is your build so far Pete. A cracking bit of workmanship on the front end rebuild mate. I will be keeping an eye on it to see how your getting on :thumb:

Glad your making a recovery after your crash. Explains why your always on MIG or PNG :)

Cheers. Did abit on getting my engine finished this week. Will go back to my mums tomorrow, as the postman has been good to me this week;) ! Will get some pics and post them up!

Yeah, spending a fair bit of time on the forums. Has certainly given me fresh motivation to get the thing finished!!

:thumb:

First time I've read your WIP mate. Sorry to hear about the bad luck! Looks like it is coming together nicely now though :) Nice job on the painting mate, how did you do the underside, lay on your back with the gun?

Hopefully 2009 will be your and your Novas year bud!

Cheers. Did the underside by hand mate!!! Got some of those mini foam rollers and a brush and went for it!!! Not a bad finish and the coverage was quite good.

yeah first time i have noticed this aswell mate , looks like some good work coming on there , keep it up woukld be good to get another back on the roads

Ok, so the postman has been good to me the last few weeks. Got my polished rocker, some stainless bolts and a load of other nice bits. See page 2! Went to my mums today and made a start on getting my engine nearly finished.

http://img.photobucket.com/albums/v3...a/IMGP0271.jpg

I started by modding my rocker cover, to do the breather mod. Probably not the way most have done it, but i have spares if it all goes wrong!

http://img.photobucket.com/albums/v3...a/IMGP0272.jpg

This was the bit i was left with. Sanded down the rough edges and..

http://img.photobucket.com/albums/v3...a/IMGP0273.jpg

..bolted it in.

I then fitted the new rubber gasket and bolted it down with my collection of stainless bolts.

http://img.photobucket.com/albums/v3...a/IMGP0275.jpg

http://img.photobucket.com/albums/v3...a/IMGP0274.jpg

I also fitted my alloy crank pulley, cool running stat, my tidied up dizzy, and dipstick holder along with one of my blue samco hoses. Rust on flywheel, water damage after the fire :roll: :( will be cleaned off.

http://img.photobucket.com/albums/v3...a/IMGP0278.jpg

http://img.photobucket.com/albums/v3...a/IMGP0269.jpg

Mmmmm, shiney! Spark plug cover will have polished letters and be painted blue.

http://img.photobucket.com/albums/v3...a/IMGP0276.jpg

The shell as it sits now...

http://img.photobucket.com/albums/v3...a/IMGP0279.jpg

..it has got the rat look, not on purpose i must add. Water plus fire/smoke damage:(

http://img.photobucket.com/albums/v3...a/IMGP0280.jpg

Thats all for this week. Need to get a few more tidy up tools then will commence engine tart up next week. :)

its coming along nice

also liking the polished rocker cover

Thanks. Have been busy painting stuff this week. Hoping to finish off bodywork and get it ready to prime it in the next few weeks.

very nice mate lookin forward to the end result :thumb:

Hey Pete, i think i remember this car when you were on/in PVG, as your avatar was the same on there that you had on here till this week lol.

Looks like you've been through the mill a bit, but getting there mate, nice plans,with some nice parts too.

Scott

lol Cheers bud. Yeah been abit of a lost year this year! But if i stay at the happy Honda factory, plenty of time off to get stuff done!

Roll on '09 and some warmer weather! The cold is a motivation killer!

PS: what part is it you cut out from the breath plate to do the mod,lol i cant figure what part you cut out?! And I'm not 100% sure if i got this done when my engine was at Dar's, best ask him..

The end part that covers the outlet pipes. I binned the rest! Probably not the way most do it, but hey!!!

The breather mod is spot on and the same as Dar did to mine.

Ok...been awhile since i have done any work or updating so...

Engine is now pretty much finished. Inlet manifold is on, brackets, dipstick etc...

http://img.photobucket.com/albums/v3...n/IMGP0654.jpg

http://img.photobucket.com/albums/v3...n/IMGP0655.jpg

So have been sorting the shell ready for the bodyshop to paint it next month fingers crossed!! Today i butchered the rear n/s arch (i am no expert welder or bodywork artist, but am on a budget and sometimes this is the best way to learn. Alsothe sideskirt will cover any imperfections lol lol)

http://img.photobucket.com/albums/v3...n/IMGP0646.jpg

http://img.photobucket.com/albums/v3...n/IMGP0647.jpg

Once cut out, found i had abit of rot in the inner arch aswell so sorte this, not a bad job if i do say so myself..

http://img.photobucket.com/albums/v3...n/IMGP0649.jpg

Then tacked in the repair piece..

http://img.photobucket.com/albums/v3...n/IMGP0650.jpg

Then welded it up and ground it back..

http://img.photobucket.com/albums/v3...n/IMGP0651.jpg

I then slopped some primer on it for now. Will give it a skim of filler before it goes for paint. Hoping to get alot more done in the next week or so. Will updated and upload pics as i do..

wooo , nice engine fella :thumb:

Did abit more today, but wasnt a good day :roll: lol :mad:

Started on sorting my front end out. Wanted to have a mock fit up. Wish i hadnt bothered, it looked shocking!

http://img.photobucket.com/albums/v3...a/IMGP0663.jpg

Holes appear to be in the wrong place for fitment of headlights and indicators.

http://img.photobucket.com/albums/v3...a/IMGP0662.jpg

Gap between the door is shocking and uneven. Where the wing meets the top of the A post is massive aswell.

http://img.photobucket.com/albums/v3...a/IMGP0665.jpg

http://img.photobucket.com/albums/v3...a/IMGP0661.jpg

Looking at the above pic it doesnt look bad but in the flesh it is awful :mad: I have put a thread in styling to ask some of you fellow mk2 owners to measure your cars and help me out lol PLEASE!! I work with new cars so fit and finish stands out a mile to me and i am also a fussy git when it comes to panel gaps!! Thread here..\/

http://www.pngclub.com/forum/showthr...15#post1109215

I then cut these in my B post..

http://img.photobucket.com/albums/v3...a/IMGP0667.jpg

/\ These were not with out there problems either...cut the too big so some modifying was in order!! Everything now fits as it should.

Made a start on fitting the clips for my side skirts aswell but didnt get very far. Will get more next week. Going to try and keep some sort of momentum going now to get it finished before i go back to work in June.

Update: my front end fits!! Yay!!! Had to grind a load away on the headlight panel. This was stopping the wings from coming in and meeting the headlights. Have assembled it and fitted headlights and grill, and all looks ok. Will dis-assemble clean and paint the insides of the wings and refit and they can stay on now lol

Nothing major but a good day for me. More next week.

Good work Pete :thumb:

It's all coming together nicely now. Nice shiny bits on the engine, when do think your going to start to fit the engine then. Anymore plans????

Get some pics up pete :thumb: