CG's rebuild thread. PROJECT COMPLETE

[craig green]

This is the WIP thread for my Nova GSi. Ive owned it since Sept 99 when I bought it as a completely std H reg GSi in flame Red. I am a bit of a purist when it comes to Nova's, so although I planned to modify it heavily I always wanted it to look like a Vauxhall product & not fall into the trap of sticking all manner of boy racer hardware on it.
Sadly I have no pics of it as I bought it. It was on std 3 spoke GSi wheels, std ride height & had the hagglers bonus of shot fr brake pads, bold fr tyres & an almost vacant clutch.
Within weeks of owning it I had replaced the clutch, had the bolster wear on the fr seat repaired & generally serviced all round incl new GM freedom battery, water pump, tensioner & cambelt + 2 new tyres on the 14" 3 spokes.
I always knew in the back of my mind I wanted have the original 1600 powerplant turbo charged. 3 reasons. 1 was to keep the originality of the factory engine numbers etc. 2 was because I didnt want to join the usual list of people using the easy route of an XE or LET to make there Nova quick. 3It is well documented that a big twin cam lump has a negative effect on the handling characteristics of the Nova, tbh it is this attribute that makes a Nova such an enjoyable experience for me. To detract from that would be madness in my eyes.
So a 1600 8v turbo it was to be. After 2 years of gentle modding of the std car. 15" team Dynamics Monza's, GSi 16v calipers, Bilstein streetline suspension (crap btw), SEAT ibiza splitter, Powerflow custom S/S exhaust & K&N panel filter. The engine was removed for a full rebuild incl new pistons aswell as a Courtenay cam & CS15 big valve head. The 1000th running in mile passed whilst enroute to Courtenay in Norfolk (some 5hrs from my neck of the woods). 2 weeks later I returned to North Walsham & had the joy of driving home with over 60% more torque & a fluttering wastegate.
Here just days after returning from Courtenay Sport....

8valve turbo engine bay...

That was 2001, the engine has been sold on due to issues with fuel injectors & bigger plans. The car also saw an almost bare shell rebuild in 02 wher it had a new passenger door, custom vented bonnet & new fr panel. The mandatory 16" Speedline Alessio wheels also went on as did KONI suspension, rosejointed TCA's, polybushes etc Whilst the engine was removed, the bay was strengthened with the Harry Hockley Grp A chassis plating kit & the bay was sprayed flame Red.
Over the years in my ownership the rear end of the car always likes to surprise me with rust issues come MOT time which currently brings me to the latest rebuild. The rear chassis legs are so shot that I took the car off the road in Dec 03 & have only taken parts off it since.

Now my Nova fetish has bitten again.. let the rebuild commence. This time I dont care for how genuine the car is, there are far tidier GSi's than mine. It is to be built as a fast road car that I can use for track days & shows.
Prior to work starting...


Progress so far.. The rear turrets are going in...


Heres the turret being fettled & cut ready to weld in.

Also we have used the original mounting lugs from the shell on the upper turret face


Heres the new powerplant btw...


CG

[ade]

looking good! Know what you mean about being bitten by the nova fetish!

[craig green]

LOL. After I took it off the road I got into Cav GSi's & GTE 16v's & just generally looking after myself living at my own place. Been back on here regularly since xmas & been driving a 1.2 beatertm though & cant wait to get back behind the wheel of the old girl.

Here it is on the trailer leaving.

[Ste L]

looks like its going to be a good project, its going to be a stipped out track/drag beast or a full car, i.e interior etc etc

[Adam]

Nice one, should be cool when finished

[Nath]

just out of curiosity how much did courtney charge for a turbo conversion?

[Ste L]

im sure its like 2 or 3k for turboing the 1.6 8v

[Nath]

maybe ill give it a miss then . but great car mate, keep us all updated!!

[craig green]

The car will likely be semi stripped. I'm not going to totally ruin it by chiselling off the seat mounts etc straight away. As it is the new rear turrets wont be in the way of the rear seat mounts, so it could have the rear seats in although I was expecting to lose them tbh. Ive got no immediate plans for buckets either so I will say its gonna have a full interior for now.

I paid ?3k for the basic Courtenay job. I had a cam & cyl head too aswell as some springs so I think I spent ?4k

[Lee]

3It is well documented that a big twin cam lump has a negative effect on the handling characteristics of the Nova, tbh it is this attribute that makes a Nova such an enjoyable experience for me. To detract from that would be madness in my eyes.

tut tut, has me and dar taught you nothing

Looks like a cracking build mate!