Brett's GTE 16v - Project Pineapple

[Brett]

Its been sat on my drive a week now, so its about time I started a new diary to chronicle the re-birth of this rather well know car!

Background - I was offered the shell little over 2 weeks ago by Chip, after a day or so of umming and ahhing I just thought sod it - rust free GTE in yellow, I really have to have it!! I trailered it back from near Oxford last weekend and got on with the process of being chuffed with it!! Of corse its best known as Gary Pooles old car, it was featured in the first issue of Total Vauxhall back in September 2001.

My plans for it involve using a lot of the bits from my old GTE, the cage, brakes, wheels and the interior in particular. I'll also be swapping the entire loom from the grey one into the yellow shell so I can fit my customised dash. I'll also be chanmging the bonnet and front bumper. I dont want to set to many plans though as TBH, plans never seem to be followed with projects like this!!!

Here it is at the moment, I havent done much except clean it out inside just so I can tell whats been done to what. Im going to take the dash out tomorrow to get a better idea of whats going on behind there, but untill the old grey GTE is out of the way I cant really do to much to this one!

As it is now;
http://xs41.xs.to/pics/05320/DSCN1445.JPG.xs.jpg (http://xs.to/xs.php?h=xs41&d=05320&f=DSCN1445.JPG)
http://xs41.xs.to/pics/05320/DSCN1446.JPG.xs.jpg (http://xs.to/xs.php?h=xs41&d=05320&f=DSCN1446.JPG)

I'll keep this updated over the next....well however long it takes:D

[Anthony]

Really looking forward to seeing how this one turns out mate, should be a cracker! :D

I didn't even realise Gary had sold it! :eek:

[Tom]

Sweet Brett :D

Remember reading about this car in that issue of TV, in fact I`ve still got it somewere, Think I`ll go have a look for it :)

[GTE16v]

looks a nice project there Brett,

can someome scan in the TV article?
.

[Gander]

Mmmmm good enough to eat, not seen a pinaple chunk that big since a Tesco's Ham and pineapple pizza back in '98 :p

[Astraoid]

Ahhh, The Traci Lords of GTE's.

[astrasteve23]

why are you changing the front bumper? thought you were keeping it but just gettin rid of the indicators in it?

[Brett]

cheers for the comments:D If anyone could scan the feature and put it up I'd be delighted! havent seen it yet as TV didnt reach our neck of the woods it seems till issue 3 meaning Ive never seen the first 2.

Got the Dash out the other night in preperation for stripping the old loom out. this is the job im looking forward to least really, I hate wiring!

Im changing the front bumper as this one has a couple of cracks and also has the foglights, the one I want to fit is an early one without the fogs.

[Tom]

Ive got the issue Brett, I`ll give it a go scanning it tonight :)

[astrasteve23]

are you keeping the splitter brett?

[Tom]

Working on it lol

http://img292.imageshack.us/img292/3761/gte49uf.th.jpg (http://img292.imageshack.us/my.php?image=gte49uf.jpg) http://img5.imageshack.us/img5/4931/gte36ky.th.jpg (http://img5.imageshack.us/my.php?image=gte36ky.jpg) http://img344.imageshack.us/img344/2264/gte27wt.th.jpg (http://img344.imageshack.us/my.php?image=gte27wt.jpg) http://img366.imageshack.us/img366/4807/gte16aa.th.jpg (http://img366.imageshack.us/my.php?image=gte16aa.jpg) http://img292.imageshack.us/img292/9083/gte58hp.th.jpg (http://img292.imageshack.us/my.php?image=gte58hp.jpg)

[DarrenH]

dear dear gary, like a young nicholas cage

[alistair j]

like the colour of that always loved garys car.

[Brett]

Kind of come to the conclusion over night that it'll be pointless putting the interior back in. Going to price up yellow and black bucket seats, harnesses etc. My cage is going to be sprayed yellow and the inside of the car is going to stay black.

The splitter is going to be swapped onto the other bumper, so yes Im keeping that.

Cheers for putting those scans up Tom, Ive been offered the magazine over MIG now too:D

and a big thanks to Gary who has been good as gold, awnsering all my questions and posting me the V5 first class over the weekend:beer:

[DarrenH]

its the old T5 volvo colour isnt it ?

[Brett]

I thought it was pineapple yellow the Mk3 Astra Sport colour!

will have to get round to asking Gary that!

[astrasteve23]

it does look a bit brighter than pineapple yellow.

[alistair j]

yeah defo brighter is nt it

[DarrenH]

ahaa, ressurected from the astrasylum


Not unsurprisingly, fairly major changes have happened in this department, the most obvious being a complete respray in Vauxhall pineapple yellow, other changes include a twin headlamp conversion, 17" Speedline Mistral wheels, a replacement front spoiler lip and a ton of colour coding and detailing including the obligatory bee-string aerial and oval side repeaters.

[Tom]

Will have the rest sorted tonight at some point :)

Sorted, post edited above :cool:

[astrasteve23]

acording to the scan that tom has put up it is pineapple yellow!

[Brett]

having spoken to Gary - it is pineapple yellow as I thought, its just a bit darker then normal because of the original paint carmine red paint underneath.

should make paint matching fun.....:D

[alistair j]

ha very true, dulex cant even help with that one.ha ha

[DarrenH]

my quote was from garys website !!!

[Brett]

been busy on it today, getting ready to get the bottom end and box out to give back to chip sometime this week. Just waiting for steve to come over at the moment as my socket isnt big enough to fit over the threads on the end of the driveshaft to get onto the nut!! bastard!

http://xs44.xs.to/pics/05351/DSCN1451.JPG.xs.jpg (http://xs.to/xs.php?h=xs44&d=05351&f=DSCN1451.JPG)

took the dash out last sunday... wiring carnage!!
http://xs44.xs.to/pics/05351/DSCN1452.JPG.xs.jpg (http://xs.to/xs.php?h=xs44&d=05351&f=DSCN1452.JPG)

made a start at least!

[Brett]

Engine came out monday night, giving that back to chip soonish as need it out of the way.

Spent a couple of hours removing the loom from the engine bay tonight, nearly got it all. Was being careful not to cut anything unless I had to as Im giving the loom to Rob SBD16v. Rewiring it doesnt look like it will be to bad a job now thank god - as long as I label everything as I remove it from the old car it should'nt be impossible!!

[Brett]

righto, end of the mont time for another update!

The car is completely stripped now. Ive given the engine that was in it back to chip and paid him for the car too! Having got the engine out I got one with removing all the loom from the car. Rob (SBD16v) wants this so it wasnt a case of juist ripping it out I spent a day removing it and pulling it through various holes bit by bit. Even the wings had to come off! Nightmare, but in the end I only had to cut it in 3 places!

All that left a fookin massive pile of wires....
http://xs48.xs.to/pics/05392/DSCN1488.JPG.xs.jpg (http://xs.to/xs.php?h=xs48&d=05392&f=DSCN1488.JPG)

And a pretty bare bulkhead, this would normally be swarming with wires etc...
http://xs48.xs.to/pics/05392/DSCN1489.JPG.xs.jpg (http://xs.to/xs.php?h=xs48&d=05392&f=DSCN1489.JPG)

This leaves the inside of the car nice and accesible so that I can have it stitch welded. With this in mind I turned my attention to the engine bay and spent a few evenings stripping everything out of that. Steering rack, master cylinder and servo, heater motor, radiator and oil cooler etc etc all removed and boxed up for the time being. All that Ive got left to take of is the ARB. New wishbones are on the to do list as the bottom ball joint bushes are knackered.

naked front end...
http://xs48.xs.to/pics/05392/DSCN1483.JPG.xs.jpg (http://xs.to/xs.php?h=xs48&d=05392&f=DSCN1483.JPG)

More Mk2 Astra nudity...
http://xs48.xs.to/pics/05392/DSCN1484.JPG.xs.jpg (http://xs.to/xs.php?h=xs48&d=05392&f=DSCN1484.JPG)

Im going to have to sort something out for the slam panel. Gary modified it at some point for reasons unknown, but a side effect is it removed a lot of the strength from it.

At this point I turned to my old Grey GTE 16v. I finally found somewhere to keep it so its final days will be seen out on the back of a mates Garden Centre:( Ive spent most of the last 3 week working on this one rather than the yellow one. A big thanks to joey (Gander) who came down last week and helped me remove the rear beam, front legs and petrol tank which he wanted. I'd already been down and started the stripping process.

Shes looking pretty sad right now:(
http://xs48.xs.to/pics/05392/DSCN1478.JPG.xs.jpg (http://xs.to/xs.php?h=xs48&d=05392&f=DSCN1478.JPG)

Today I went up to the grey car again and removed the custom dash some of you will remeber me building this time last year. The summer heat hasnt been kind to it casuing it to crack in 2 places, and the flock was peeling. I blame this on the vinyl heat wrap the dash has as standard - Ive peeled it off this afternoon so its down the the card. This should be a much better surface for me to fibre glass onto and then flock onto.

http://xs48.xs.to/pics/05392/DSCN1487.JPG.xs.jpg (http://xs.to/xs.php?h=xs48&d=05392&f=DSCN1487.JPG)

Hoping to get the engine out of the grey car this week, and have the rest of the stitch welding done on the pineapple. after that its on with the spraying and re-wiring:D

[Sipo]

Im an electrician mate but i tell you, I HATE car electrics! I cant stand working on them I really cant! Its a shame to see your grey one end up like it has, but you are moving to better and less rustier thiings i suppose! Keep up the good work mate, I really need to try and pop down to see you and Steve soon to look at both of yours progress!

[Tom]

Wow you`ve been busy :eek:

Not hanging about are you, lol

Grey one is looking very sad there Brett :(

[Brett]

Steves progress extends about as far as moving his GTE from Craigs garage where it was to another mates field LMAO!!! steve said you were gonna come down last week? make sure you let me know if you are matey!

Car electrics are my worst enemy too. I once burnt my little finger down to the bone when I used to thin wire in a circuit.. it heated up, the flex caught fire, I grabbed it thinking the whole car was gonna go up.... oh the pain!

[astrasteve23]

i think si is on about the progress on the van! which still isn't MOT'd! lol. have to check it over tomorrow night and hopfully MOT on friday.

[astrayorkie]

. I once burnt my little finger down to the bone when I used to thin wire in a circuit.. it heated up, the flex caught fire, I grabbed it thinking the whole car was gonna go up.... oh the pain!
lol got priorities right mate car before self :D

just started a evening class on auto electrics and electronics alot harder than i thought :confused:

[Brett]

evening clases suck dont they, Im in year 1 of 3on an accountancy course 2 nights a week and it leaves no time to work on the car!!!

havent touched the car since last week. My Old XE has been sold to a bloke who picked it up last night, its bound for a MK2 Cavalier Calibre (nice cars IMHO) Next step is to remove the loom from the grey one and remove any wores I dont want from it. Should keep me busy as I spent the stitch welding fund on a Calibra 16v on saturday!

[Brett]

well the weathers to crap to get up to the GTE in the evenings now so Im busying myself relocating the electric window switches and mirror switches to the dash where the ashtray once was. I dont want any wires on the exhaust tunnel, between the 2 seats.

Would it be safe to run the brake lines and fuel lines along it, given that this part can get a bit hot with heat from the exhaust? that would look great having them come through the bulkhead, then along beside the gear stick and between the two seats, up into the back. Nice easy route too as it would avoid having to run them over bumps and round roll cage pillars!!

[DarrenH]

i reckon so. seen it done on quite a few cars. and ive never felt my tunnel and it been hotter than you can hold your hand on. so i reckon about 50 deg C. wonder how hot the lines and fluid get near the caliper on a track day, eh :)

fuel lines you gotta be careful though, its gotta be all threaded unions in the car, no rubber hose and jubilee clips for obvious reasons

[Brett]

cheers, Im aware of whats involved in having fuel lines in the car, been thinking about it for ages:D Remeber mine is going to be on the darkside with a LET LMAO I'm unsure but tempretures might be higher coz of this?

another thing I heard recently which you might be abke to help with actually mr 0dders - Gary has put braided hoses right through the car - from the master cylinder to each of the callipers. I thought great when I spotted it, but now Ive been told that its dangerous as full length braided hoses have a habit of bursting?? not heard it before but feel I ought to check!!!

[DarrenH]

not heard of that. wouldnt be too much bother to replace with copper anyway. hose is pennies and flanging kit is 12-15 on machine mart.

[Brett]

good if its news to you to! if the braded stuff is there and works - why change it? Its more practical too, its easier to move around, change routeing if Im not happy etc etc.

if it aint broke dont fix it and all that!!!

[pajero1]

Alot Of People Use Copper Pipes Overbraded To Run Pipes Inside The Car,my Old Mk2 Escorts,nova Rally Cars I Just Used Nickel Cadium Pipe Or You Can Get Stainless Pipes

[Brett]

another month or so has passed, so heres another update on progress.

Its not as much as I'd planned. As Im sure you'll all know by now I bought a Calibra 16v as slow cars were just driving me nuts. So the welding fund now looks more like a Calibra:D

Instead Ive been busy working on the grey GTE and bits for the yellow shell. The grey GTE now has no engine and all the loom has been removed. Theres not much left now!!
http://xs53.xs.to/pics/05444/DSCN1577.JPG.xs.jpg (http://xs.to/xs.php?h=xs53&d=05444&f=DSCN1577.JPG)
http://xs53.xs.to/pics/05444/DSCN1581.JPG.xs.jpg (http://xs.to/xs.php?h=xs53&d=05444&f=DSCN1581.JPG)

The dash is taking shape, Ive just finished with the fibreglass so its ready for sanding. I also used more expanding foam to keep the weight down this time.
http://xs53.xs.to/pics/05444/DSCN1582.JPG.xs.jpg (http://xs.to/xs.php?h=xs53&d=05444&f=DSCN1582.JPG)
http://xs53.xs.to/pics/05444/DSCN1583.JPG.xs.jpg (http://xs.to/xs.php?h=xs53&d=05444&f=DSCN1583.JPG)

The main task at the moment involves the loom. I want thew car to look tidy when its done plus with the custom dash, there will be lots of things i wont be using so dont need the wires for. Its a bit of a messsy job!! I owe a huge thanks to Steve Heley for the massive long peice of paper you can see in the pics, its a wiring diagram and its so usefull its unbeliveable!!
http://xs53.xs.to/pics/05444/DSCN1584.JPG.xs.jpg (http://xs.to/xs.php?h=xs53&d=05444&f=DSCN1584.JPG)
http://xs53.xs.to/pics/05444/DSCN1585.JPG.xs.jpg (http://xs.to/xs.php?h=xs53&d=05444&f=DSCN1585.JPG)

So far Ive removed;
Brake pad wear sensor wires
rear speaker wires
trailer loom (7 wires!)
lights on warning buzzer loom and relay
front fog light wires
headlight height adjustment wires
analogue clock wires
dual horn relay and wires

still lots more to come out too!

I also plan a few other mods to the loom. Im going to be doing away with the check control display, but I plant to relocate some of the functions into the digi-dash. These are the oil level, coolant level and brake fluid level warning lights. Theres space in the dash for the extra lights and by cutting the symbols for the check control and putting them in the digidah I can even have the right symobols. There are 5 (I think) unused wores in the digidash black connector so I plan to simlpy connect the wires from what was the check control to these unused wires and, hopefully, hey presto! Anyone know if this will work? LOL!

Im also going to move the electric window and mirrors loom to the main loom behind the dash and have the switches where the ash tray was.

Yesterday I ordered around 15m of conduit from Frost auto restorers to give it all a nice clean look. Also ordered more flock for the dash:D

Brett

[Brett]

a few developments on the shell front!!

found someone to beed blast the engine bay, my mate craig is going to weld it at his brother MOT centre with the ramps and everything:D should mean the welding job is a goodun:D

Just hope I can jell the blasting-welding-painting process together so it all happens!!

[CraigGreen]

looking & sounding good Brett, nice one for getting it blasted. That will help no end.

PM me if ya fancy meeting up again soon.

[Brett]

cheers craig, you have a PM!

[Brett]

Ive got today and monday off work so heres another overdue progress update.

Im looking at a Calibra Turbo on sunday with a view to using its engine in this car:D at feckin last!

Loom is done too which is good news! full list of whats gone:
Brake pad wear sensor wires
rear speaker wires
trailer loom (7 wires!)
lights on warning buzzer loom and relay
front fog light wires
headlight height adjustment wires
analogue clock wires
dual horn relay and wires
Headlight washer relay and wiring
heated rear window
Check control (the whole lot, sensors, display unit and control box)
Electric & heated mirrors loom (included a huge relay!)

plenty more went but that the bulk of it. Final weight of wires removed was 10.7kg's -thats the extra weight of an F28 box' out of the loom I think.

Today I have sprayed the cage in primer, its going gloss black in this car.

[astrasteve23]

i might bring my GTE home on sunday brett so i might need help/advice on chopping my loom about, 10.7kg's is a fair bit of unwanted weight!

[Brett]

mate I was going to suggest later at the pub, we should bring it back to yours this weekend. Want to get the sunroof and RS seats from my car tomorrow? need to get the glass out or it this weekend anyway, and I could do with a trial for of the cage too tomorrow!

Hang on why are you at home? your supposed to be on the way to mine to give me a lift to the pub! WTF!

[astrasteve23]

lol. cant get hold of craig! i wont be about tomorrow but i will be first thing on sunday morning if you wanna get the bits then?

[Brett]

change of plan, the cars going to craigs house tomorrow as theres more space to work on it there:D

should speed prgress up somewhat!

[astrasteve23]

is craig gonna weld it up?

[Brett]

nah its still going to counsells mate, needs to have the rust seen to, and they'll have ramps to do a really really nice job if it.

[Brett]

This morning the Yellow GTE was sat on the drive, I was unsure when i'd be able to get some proper jobs done on it due to the freezing weather lately and I had no engine for it.

What a difference a few hours make! the cars now moved to my mate Craigs house (same place as steve's GTE was welded up before he put the shell out-to-grass!) once again another mate, Tom, lent his time, van and trailer to help with that job:D

loaded up
http://xs58.xs.to/pics/05490/DSCN1606.JPG.xs.jpg (http://xs.to/xs.php?h=xs58&d=05490&f=DSCN1606.JPG)

time for a bit of mincing around, tom (standing) and craig (sitting) style...
http://xs58.xs.to/pics/05490/DSCN1608.JPG.xs.jpg (http://xs.to/xs.php?h=xs58&d=05490&f=DSCN1608.JPG)

On craigs garden while we cleared his garage out...
http://xs58.xs.to/pics/05490/DSCN1609.JPG.xs.jpg (http://xs.to/xs.php?h=xs58&d=05490&f=DSCN1609.JPG)

By darkfall, we had got it inside and it was time to trial fit the rollcage. I was dreading this as although Gary had a Saftey Devices 6 Point bolt in cage fitted to it, which is identical to mine, no 2 cages are the same:( some blood, tantrums, tears and a bucket load of sweat later we had the back in:D only one hole is too out so far, I was delighted! Thats where we called it a day for now, We're going to fit the rest of the cage in on Tuesday night.

Cage is still in primer, Its going to be gloss black.
http://xs58.xs.to/pics/05490/DSCN1611.JPG.xs.jpg (http://xs.to/xs.php?h=xs58&d=05490&f=DSCN1611.JPG)

For those of you that read my other thread about the Cally T, I looked at that first thing this morning and got it for the price I had in mind, should have that MOT'd and on the road in the next few weeks. Picking it up next Saturday! any cant wait gen!

so tonight, the car is in a place where the rate of work can really pick up, and Ive got an engine for it. Its great when things start to take shape!

[teej]

I must have a much older SD cage, then, as mine doesn't have a cross piece at the back. Wish I could get my finger out of my arse and get as much done as you have!

[DarrenH]

cage went in a peice of pish through the passenger door on mine.

[astrasteve23]

what do you plan to do to it whilst its at craigs? is he gonna weld it now?

[Daza]

Looking good Brett. I look forward to seeing the finished artical!

[Harvey]

Wow, nearly at the stage my shell is at. My body shop man is hoping to get everything ready for pickup this coming Sat. I've stole Oddballs idea with the seat mounting as I was going to mount on the OE sub frames but chucked that idea in favor of mounting them 2" to 3" lower.

[astrasteve23]

Finance was sorted out today, so its full steam ahead. Plan is to have the car done by March, hopefully it'll be driven out of Craigs garage - thats how long its going to be there!

Odders - I did put the cage in through the drivers door, smacking my shin trying to squezze it passed the steering wheel. That was the blood and sweat bit. Bending down and not noticing the axel stand before my ball sack crashed into it - that was the tears and tantrums part!! by getting it in I mean lining the plates up so we could bolt it in!

I'm off to look at tghe oddball seat mod, anything that lowers the centre of gravity gets me interested!

[Brett]

Thats was me, Im on steves computer and forgot to log in LOL!

[Harvey]

I'll get some pics of the seat mounts when I pop down this coming Friday afternoon and post then in my build diary so keep your eyes peeled, that is providing they have do the welding as I'm hoping to pick it up this Saturday. I can then start on the custom wiring as I'm making my own fuse box on the passenger side and ripping out all the stuff I don't need.

[Brett]

picked this up today, donor car for the engine. I'll XE the shell and use it as my everyday car....

The bloke I bought it from bought the car brand new in 1992 and paid nearly £25k for it with the extra's such as the kit. I've paid him just £1200:D 101k with a FVSH, it had a new head at 80k and the cars very tight to drive. Inside the car is immaculate with the exception of the headlining which Im going to replace. The bodywork is reasonable, the arches are starting to go, it needs a spot of welding on the sill too. The kit IMHO looks fantastic though.

Obviusly the TXB is knackered!

http://xs59.xs.to/pics/05502/BrettCallyT.png.xs.jpg (http://xs.to/xs.php?h=xs59&d=05502&f=BrettCallyT.png)

http://xs59.xs.to/pics/05502/BrettCallyT2.png.xs.jpg (http://xs.to/xs.php?h=xs59&d=05502&f=BrettCallyT2.png)

The car hasnt been used regularly since September 2004 when the TXB blew, the owner is very sentimantal about it and wouldnt sell it to me first time I asked about the car. He planned to store it untill he needed it again. It failed an MOT last week on some small things and the guy e-mailed me telling me to make a reasonable offer.

Im planning a full service on the car for staurday, so any advice people can give me on what things I should replace and the best parts, Im looking to do leads, plugs, rotor arm, dizzy cap, fuel filter etc etc... I plan to use the LET for the Astra GTE and XE this turbo shell and use that as my everyday car.

[Brett]

Things have been progressing really well of late, the car has been consuming lots of my time which is why I havent been around as much as normal of late. Now its in my mate Craig's house in his garage, Ive been able to crack on in the dry (if not warm!) at least. Ive also been buying plenty of bits and bobs for it.....

sorry if its a long thread, and also sorry for the poor pictures, most of the time I cant be arsed to stop for some silly pictures, but I know if I dont I'll only regrett not having them to look back on!!

as it was on arrival at craigs...
http://xs64.xs.to/pics/06030/DSCN1612.JPG.xs.jpg (http://xs.to/xs.php?h=xs64&d=06030&f=DSCN1612.JPG)

Before any welding was done I cedided to trial fit my roll cage into it to see if it lined up with the existing plates. It did which was great, but the A pillar mounts need replacing, the bolts wont tighten up:(
http://xs64.xs.to/pics/06030/DSCN1610.JPG.xs.jpg (http://xs.to/xs.php?h=xs64&d=06030&f=DSCN1610.JPG)

next we tackled the engine bay. There were some rust holes I wanted tidying up, and also some plating needed on the inner wing on the passernger side. Its a testiment to how well Gary kept the car in that the only other place Ive had to repair rust is the traditional spot, drivers side floorpan wishbone mount area. Craig welded for me, its like art when craig welds, its just so damn tidy!
http://xs64.xs.to/pics/06030/DSCN1648.JPG.xs.jpg (http://xs.to/xs.php?h=xs64&d=06030&f=DSCN1648.JPG)
http://xs64.xs.to/pics/06030/DSCN1644.JPG.xs.jpg (http://xs.to/xs.php?h=xs64&d=06030&f=DSCN1644.JPG)
here we are filling a large hole that had been cut by holding a peice of copper on one side and welding the other side.
http://xs64.xs.to/pics/06030/DSCN1657.JPG.xs.jpg (http://xs.to/xs.php?h=xs64&d=06030&f=DSCN1657.JPG)
an example of the finished welds - this one is on the chassis leg to the inner wing passengers side
http://xs64.xs.to/pics/06030/DSCN1649.JPG.xs.jpg (http://xs.to/xs.php?h=xs64&d=06030&f=DSCN1649.JPG)
turrett
http://xs64.xs.to/pics/06030/DSCN1650.JPG.xs.jpg (http://xs.to/xs.php?h=xs64&d=06030&f=DSCN1650.JPG)

In the end, I elected to go for a mix of seam and stitch welding. We seamed the chassis legs and engine mounts, and stictched the suspension turrets to the inner wings, the sterring rack box sections to the bulkhead, all round the wishbone mounts too.

Next we fitted a new slam pannel as I wasnt happy with the lack of strength in it, lots had been cut away. This turned out to be a bitch of a job, findng all the spot welds, drilling them out, lining the new panel up and holding it there while we spot welded it back in. I wont ever do that job again!

next job on the list was getting it ready to be sprayed, and this is on going. I knew it would take this long but I have cramp in my arm Ive been sanding so much filler in places!!
Engine bay is noe done, baring a few more holes I have decided to fill. Here it is in primer awaiting the top coat....
http://xs64.xs.to/pics/06034/DSCN1798.JPG.xs.jpg (http://xs.to/xs.php?h=xs64&d=06034&f=DSCN1798.JPG)
tidying repair to the wishbone mount
http://xs64.xs.to/pics/06030/DSCN1805.JPG.xs.jpg (http://xs.to/xs.php?h=xs64&d=06030&f=DSCN1805.JPG)
finally started nasking up last night, still some fillering and prep tp do but all being well that'll be done by the weekend.
http://xs64.xs.to/pics/06030/DSCN1807.JPG.xs.jpg (http://xs.to/xs.php?h=xs64&d=06030&f=DSCN1807.JPG)

I bought a litre of Pineapple Yellow two-pack at the weekend, along with the thinners and hardeners needed. Craig has a compressor and we have a spray gun, so in a weeks time I should be able to report the car is yellow all over. I plan on leaving all that to properly set for a week before I go climbing around in it, first job will be to re-wire the whole bloody thing. Cant wait:D

Ive been buying lots of other bits too, heres some of the interesting stuff...
Bucket seats - Corbeau Forza Sport 2000. FIA homologated too, although no idea if they meet current regulations!
http://xs64.xs.to/pics/06030/DSCN1777.JPG.xs.jpg (http://xs.to/xs.php?h=xs64&d=06030&f=DSCN1777.JPG)
Frontera 2.8TDi FMIC
http://xs64.xs.to/pics/06030/DSCN1811.JPG.xs.jpg (http://xs.to/xs.php?h=xs64&d=06030&f=DSCN1811.JPG)
Digital AFR and Boost guages, and the face plate Ive made up for them to sit in the extra pod I have on my custom dash
http://xs64.xs.to/pics/06030/DSCN1809.JPG.xs.jpg (http://xs.to/xs.php?h=xs64&d=06030&f=DSCN1809.JPG)
and a chrome SP cover. Im going to paint it black but leave the wording on it chrome:D rocker and cambelt covers are going to be yellow.
http://xs64.xs.to/pics/06030/DSCN1814.JPG.xs.jpg (http://xs.to/xs.php?h=xs64&d=06030&f=DSCN1814.JPG)
Finally this turned up opn E-bay last week, I wasted no time LOL!
http://xs64.xs.to/pics/06030/DSCN1810.JPG.xs.jpg (http://xs.to/xs.php?h=xs64&d=06030&f=DSCN1810.JPG)

I have also liberated the LET from the lump of lead it was attached to (AKA Calibra Turbo shell) I've also found the time to fit the bumpers from that to my Calibra 16v runaround along with vectra doorhandles and the Trip computer for the turbo.

I've added this thread as a reply in my diary in the restoration section, so if you've been following it there fell free to reply there LOL!

Brett

[Orange Peel]

Good work mate. Really like the seats.

Nice to see things are moving along :)

[astramad]

well done mate
how did you get on with the gearbox flange???

[Gteman]

Slow down your showing me up.

Just realized I've never posted in this thread thought i better leave my mark

http://www.clicksmilies.com/s0105/wuerg/vomit-smiley-026.gif

Cars lookin feckin great m8 a lot of work put in there. http://www.clicksmilies.com/s0105/travesmilies/smilie_daumen1.gif

[Brett]

cheers lads. its coming on nicely now.

Astramad, I havent fitted the kit yet mate. havent touched the engine since getting it out, sorting the rest of the car out first.

[Harvey]

Looking good bud, can't wait to see the finished article. Just wished I could afford a LET but I'm sure my stock XE will do me fine.

[Brett]

LOL I only went for a LET as its cheaper to get serious power out of as opposed to the XE.

On the track a standard XE just didnt feel fast enough to really make me scared!

[mking]

looking good mate, love it!

[Tom]

Looking good Brett :D

Looking forward to seeing this finished :)

[Brett]

I booked thursday and friday off work to really crack on with this, the aim being for me to be spraying it today.....

but Ive had some sort of mysterious ailment, and Ive pretty much been in bed since wednesday morning so I havent touched it at all:(

2 holiday days pissed away and no astra progress:( Im feeling much better today so I might go and get the dash and crack on with that at home later in the warm. Still not 100%:(

[Harvey]

Same here Brett, still got the reamins of my cold so not really done much to mine apart from take more bits off.

[tomstickland]

Great stuff, I've really enjoyed reading the latest progress. It's virtual modifiying from the comfort of home without having to do anything for me.

[Brett]

cheers Tom:D

following sundays meet, I went down and crack on with this some more.

I then went back down last night and got the front wishbones off as I dont want to spray them yellow, and I want to replace the ball joints. Thankfully they came off nice and easy :D which is great because last time I did MK2 Astra wishbones it was an absolute biatch of a job!!

I finished the engine bay prep, got a high pressure air line on it and cleaned all the crap out of the hard to get places with that. So much easier. Thats now got its last layer of primer on it which will just need flating back before I paint it yellow.

Inside Ive got a few areas left to sand, then Ive got to mask everything off and get busy with the primer:d

[DICKO]

Looking good!!!! its great when its been painted and you can start putting nice shiny things back on it

[Brett]

Finally, after what feels like months (actually 5 weeks) I sprayed the car today, pineapple yellow to match the exterior paintwork...:bananajump: :bananajump: :bananajump: :Banane44: :Banane43: :Banane42:

how things began this morning....
http://xs67.xs.to/pics/06060/DSCN1844.JPG.xs.jpg (http://xs.to/xs.php?h=xs67&d=06060&f=DSCN1844.JPG)

I tidied up, moved the shell into the centre of the garage using our new skateboard method. I sprayed it with 2-pack using my mate Craigs compressor. It was my first ever attempt at spraying using a proper spray gun, it took me a while before I was happy with the way the gun was dispersing the paint but once that was sorted, I was off. I bought a litre of paint (makes 1.6l when you've mixed in hardeners and thinners) and it was exactly enough. I really enjoyed painting it, took 4 hours and I only got 3 little runs! Its come up a bit more orange-peely than I'd have liked, but its a mainly going to be a car for driving not showing off and it doesnt have to be perfect.

anyway, some pics of the finifhed effort!

engine bay..
http://xs67.xs.to/pics/06060/DSCN1852.JPG.xs.jpg (http://xs.to/xs.php?h=xs67&d=06060&f=DSCN1852.JPG)
http://xs67.xs.to/pics/06060/DSCN1853.JPG.xs.jpg (http://xs.to/xs.php?h=xs67&d=06060&f=DSCN1853.JPG)

inside...
http://xs67.xs.to/pics/06060/DSCN1846.JPG.xs.jpg (http://xs.to/xs.php?h=xs67&d=06060&f=DSCN1846.JPG)
http://xs67.xs.to/pics/06060/DSCN1849.JPG.xs.jpg (http://xs.to/xs.php?h=xs67&d=06060&f=DSCN1849.JPG)
http://xs67.xs.to/pics/06060/DSCN1851.JPG.xs.jpg (http://xs.to/xs.php?h=xs67&d=06060&f=DSCN1851.JPG)
http://xs67.xs.to/pics/06060/DSCN1854.JPG.xs.jpg (http://xs.to/xs.php?h=xs67&d=06060&f=DSCN1854.JPG)

Best moment of the day? when I peeled back the masking tape to check the colour match. Its spot on:D gary told me it was red undernatch and the paint was slightly darker, hence the red primer. Worked a treat:D
http://xs67.xs.to/pics/06060/DSCN1857.JPG.xs.jpg (http://xs.to/xs.php?h=xs67&d=06060&f=DSCN1857.JPG)

and me by the time I went home, a nice yellow hue... (I should add yes I was wearing a breathing mask, and I didnt go to bed till 5am last night and was up at 9 this morning, Bath rocks for a good night out!!)
http://xs67.xs.to/pics/06060/DSCN1859.JPG.xs.jpg (http://xs.to/xs.php?h=xs67&d=06060&f=DSCN1859.JPG)

Anyway, it feels great now its done, and its something else on the car that Im proud to be able to say I just got on and did it myself:D Really motivated to get one with hammeriting the underside and wheel arches this week now!

[CraigGreen]

Nice Job.

[astrasteve23]

seen it finnished last night, looks real good! cant wait to get mine home and start working on it!

[Brett]

cheers steve!

[Brett]

last night I began to refit a few parts to it. Back in went the rear windows which need to go in as once the roll cage is in you cant get to the scews. I undersealed the front inner arches and painted the front crossmembers black. I sprayed the handbrake and pedal box too before refitting tonight.

one job Im not looking forward to will be refitting the sunroof, the bloody scilicone that was on the roof already will not come off, so it might leak:(

its REALLY yellow now all that masking tape and newspaper has been removed, and the paint looks better than I thought so all in all, delighted with that job!

[untouchable]

brilliant stuff Brett, really cant wait to see her all finished :D

[Brett]

cheers mel!

[Brett]

A very frustrating day. Woke up feeling Ill which annoyed because I had avoided the evils of alcohol last night ready for a full day on the car.

Felt to crap this morning so arranged to meet my mate who runs the MK2 1.4 L I razzed around in for a few months last year. When I sold it i'd said about a few parts I wanted so went to get them. It was only the door seals and boot seal, Those were black ones and I wanted them for the GTE so hes now got grey! From there is progressed to the pub for a pint so I made a late start on the car.

First job was to clean and re-fit the pedal box. It cleaned up fine which was good, but when I came to refit it I realised there was no way I could do this without removing the bracket for the servo. god knows how I got the feckin theing out! 5mm allen key bolts to do it - which promptly rounded off:mad: by this point, the headache was getting worse and I was a little upset with the bolts, so the s.o.a.b pedal box got obliterated with a fook-off-big hammer.

I realised I wasnt in any frame of mind to be working on the car so took my Mk2 Cav estate beam to steves to compare the ARB's. I want to fit the ARB from the 16v beam on the astra to it as its an Eibach item, this should also make up for the loss of the additional ARB. Good news at least was it looks like it will fit the cav beam.

Im picking up a replacement pedal box from stt tomorrow morning as I'm not one to hang around, and I felt like a right cock for letting my temper get the better of me on the first one LOL!

nevermind, sure there will be more days like this!!

[Jags C20LET]

......for the servo. god knows how I got the feckin theing out! 5mm allen key bolts to do it - which promptly rounded off:mad: by this point, the headache was ..............


....eeeeeerrrr, sorry to be one one to tell ya mate, but, they are actually 6mm, and using a 5mm is probably what fukked 'em.

[Brett]

LOL would have been a 6mm one I had then, it fitted nicely - certainly wasnt a whole 1mm too small.

bloody things were so fecking tight though:mad:

[Jags C20LET]

Yeah, you're prolly right. I just changed my rack and one of the servo bolts was rounded, not by me either....probably by regals when they welded the bulkhead:hissyfit: . I had to drill the head off, and it still wouldn't come off. Eventually gathered up the courage to drill down the length of the remaining bolt shank to weaken it enough to shear it.......amazingly enuff, it worked:Banane42:

Bought 2 new ones to fit, and a spare

[Brett]

yeah I might end up doing that tomorrow.

Cant see how else Im going to get the ****er to fit though, it just will not go back in.

[GazJevs84]

shame mate cars really pi55 me off at times too there has been pointless amount of times i have nearly givin up on stuff just keep going mate it will be worth it just to see the finished product.

[Brett]

good day yesterday!!

Went to the MIG meet in Exeter via stt's and collected the new pedal box and a standard manual steering rack. Tempered by the news the quikrak from RSC ive waited a year for will probably never show up and cost me £180 for nothing. Great.

Got the heater motor and matrix back into the car last night. Started to put the loom back in and concentrated on running the wires for the interior/courtesy light that run around the windscreen and connected them up to the switches at the bottom of the a pillars. That took and hour and a hald alone.

Also out the seatbelts back in:D

[DarrenH]

have you counted the locks on the manual rack? theres two types. the one i lifted off a 1.3 was about the same locks as the PAS rack (just over 3.5), but i know larger engined manual racks are getting on for 5 turns !

[Brett]

4.7 turns on the normal rack I think!! This one came of a C plate GTE 5 door stt and I stripped last year... so likley its that kind.

Will check when I get home, but there is a 1300 in my local breakers.

cheers for the heads up!

[Harvey]

As Odders said go for a small block manual rack as they have a lower ratio than the bigger block racks, think they are something like 3.7 lock to lock but I'll check on my Starmist for you as it's a 1.4NV.

[DarrenH]

mattj bought a new manual rack and it turned out to be the 4.7 job. two yanks to get round slight corners, not good !

[Brett]

I didnt get a chance to check last night, but I did notice that its got Astra Mk2 written on it meaning its almost certainly a replacement rack, so it could be either:D

Been concentrating on getting bits for the front suspension yesterday and today.

Ive ordered new front wishbones with OE rubber bushes and new bottom ball joints, new complete ARB links (these also seam to wear away in places Ive noticed) including rubber bushes, topmounts for the legs too. In light of what 0dders posted up about Stickers feelings on the poly stuff, I feel its money well saved. The only poly bushes on the car will be the rear front wishbone mount (assuming a OE one doesnt come with the new wishbones) and the rear beam.

Need to work out which steering arms Im going to be using before I order track rods ends, gary had modified the ones os his PAS rack to avoid bump steer I beleive, if these fit the manual rack I'll use them. If not I've got some manual arms which I will use. However there seems to be 3 or 4 different thread patters on the end of these arms meaning the right trackrod end will be needed.

[astrasteve23]

mattj bought a new manual rack and it turned out to be the 4.7 job. two yanks to get round slight corners, not good !

is that the one i had off him?

[DarrenH]

dont think so, only one way to find out though. mole grips and a blob of paint !

[astrasteve23]

he said it was a re-con one done about 500 miles. the standard one on my van and old 1.4 astra is 4.2 turns.

[Harvey]

I have checked my manual rack on my 14NV and it's 4.2 turns lock to lock.

I have used my existing 16v PAS steering arms on my GTE with the quikrack and they fitted no problem.

[Brett]

havent checked ths rack yet, but I spent all last night rewireing the rear light clusters, fuel pump and foglights. Took ages mainly because most of that loom runs inside the boot sill and I was soldering it tyring to do a tidy job. Back for more tonight!!

[Harvey]

Did you get high on the solder flux?

[Brett]

yes, just alittle bit there wasnt that much flux in the solder I dont think and I left mine at home! it wasnt helped by the fact I was soldering on my own as my mate was putting the finishing touch's to his Nova 16v, so I had the soldering iron in one hand, the 2 wires in the other, and the solder clamped between my teeth, moving my head to melt it into the wires!

I couldnt wait though, and to be fair he got the Nova going and we took it for its first blast down the country lanes - what can I say absolutley mental peice of kit:D didnt feel much faster than a GTE 16v but seriosly noisey, boucing and wheel spinning in 3rd. power was almost unusable but theres a lot of positive camber, front legs need to come off again.

Cant wait for that shakedown blast in the Astra!!!

[DarrenH]

he said it was a re-con one done about 500 miles. the standard one on my van and old 1.4 astra is 4.2 turns.

yeah that rack is brand new brand new, what i meant by my previous post is that i dont know if the one you have is the one i remember with lots of lock.

[Brett]

4.2 turns is loads:(

2.5 sounded so much better. May RSC Motorsport and trevor bloody robertson rot in hell, with every single one of the £183 pounds hes robbed from me reigning down on him glowing red hot:mad:

wishbones are here, even include the rear floorpan bush and bracket. Top Quality!

[Brett]

I had hoped to update with pictures, but my digicam is broken!!

My steering rack is 4.2 turns lock to lock, apparently though I might hear something from RSC this week. I doubt it.

Ive got all the rubber seals for the doors and boot back in. Ive run all the wires for the loom to the rear of the car down to the passenger footwell. the rear lights, fuel pump, back bumper, and boot are now fully wired back in. Ive reconnected the door looms to the main loom, I had to cut these as Ive moved the electric window loom from running down the centre of the car to behind the dash, shortening it by about a metre.

replacement pedal box is now in at last, and Ive got replacement 6mm alan bolts for the servo on order from Vauxhall. When thats on I want to start getting the brake lines run.

I went to steves on saturday with interntion of stripping the Astra legs down and buliding them back up in the 5 stud Calibra legs with my new top mounts. Only the bearings are pretty ****ed in those legs, to the degree where after a good wire brushing, the hub on the drivers side fell out when I picked it up! Im now in the process of sorting out bearings for that, sadly its a 1992 leg, the year the bearing size changed so at this stage I dont know which to use. Will end up buying both!

the new wishbones are now on too, although they have to come back of because I didnt have the right washers at the time! these are on order from vauxhall to now.

I also spalashed out a bit at Vauxhall, and ordered new black plastic bump strips for the front bumper, you know the ones I mean. They are only £19.33 inc VAT each!

This weekend I hope to get the legs built, get the rear of the cage in, the servo and master cylinder on, right wishbone washers, and rack on, the front ARB and do some more wiring, route it where I want.

I'll get some pictures as soon as I can, its starting to look like a car again!!

[Harvey]

Slow down, your beginning to over take me and my now very snail like progress. Hoping to get my windows in this weekend, just praying the snow stays away as I'm building mine in the open air on my very cold drive.

[DarrenH]

for the bumper, you mean the centre rub strips and the lower chin strips ?

[Brett]

centre rub strips - Im reusing the splitter Gary had on it for the lower part, with fiesta Mk3 Si foglights as indicators to compliment with the quads.

I should be able to order the pipe kit for the brakes tomorrow, so I'll refit the servo and start working that out at the weekend. Want to get the ARB on and the steering rack - RSC dependent. Harvey tells me there is life up there, albeit a little shy of some customers!! I'll fit the rear of the cage too hopefully.

after all thats done I'll finish the loom and then, I can seeing about getting this engine in......:D

[astrasteve23]

popped in craigs and seen it earlier, coming on nicely. trevor is re opening in a couple of weeks at new place so we should hear somethinh soon!

[Brett]

Slight change of plan, its become obvious it would be far better to fit the engine, then finish the wiring for a tidy job.

So, Im going to get a few days of next week and turn my attention to the engine, get it painted, timing belt kit and water pump done. Further maintenance will be best done when the engine's in the car I think.

last night I rewired the heater motor, wiper motor and winscreen washer pump. I filled some holes up that Ive found or realised I wont use, a bit annoying considering the paint but it will tidy up fine. I put the final coat of gloss black on the cage and fitted the correct window screws, the cage can go in thursday night now after the sunroof goes back in.

still nothing on the quikraks:(

[Brett]

didnt spent too much time on it this weekend, I put in a few hours cleaning the steering rack up with the wire brush and other bits and bobs.

I couldnt find the steering rack that came with the car anywhere, I wanted this as Gary had made some clever steering arms I want to re-use. After going between my garage and craigs garage twice, I came to the conclusion it had been scrapped by accident. I was seriously miffed as theres no way I myself would have binned it. Then my brother came back from my mates garden centre where he had been stripping the heated seat loom from my Calibra Turbo shell for his Astra GSi. It hit me, and half an hour later I was re-united with the rack, which I'd put out of the way in the Calibra after removing the engine!! I also realised the front wings from the astra are still in it, which I wasnt aware off! all that cost me the afternoon!

yesetrday I went to Steves and we stripped down the Astra front legs and hammerited the Calibra Turbo legs ready for having the new bearings pressed in. After that we swapped the front legs on his van as hes got some starnge handling issues.

next update should be thursday, I've got the day of work and stt is coming up to help out. My mate craig has the day off too, so we should get shed loads done!

[Brett]

Front ARB is on at last, along with the correct washers for the wishbones.

Ive given all the front inner wings and arches a 2nd layer of underseal to stop it rusting where we've welded it.

Went to fit the cage the other night, then discovered one of the seatbelts has jammed so thats still not done. Its so frustrating that silly things like seatbelts can hold me up, It'll be the weekend before I get time to find one of those again.

Ive painted the steering rack and modified the damper on the manual racks so i can retain it and use the special steering arms gary made. This involved making the bracket that the steering arm bolts go through flat and slotting one of the holes slightly. Thats all ready to go on now, along with the servo and brake line which are being done tomrrow.

Would love to show you all some pictures, but I have none, digi cam is still away being fixed!

[BazW]

how much is left to do?

[Brett]

antiroll bar was the first thing Ive bolted back onto the front of the car except for the wishbones LOL! pretty much everything is still to be done!

lots still to do, its re-wired now thats the main thing!

[DarrenH]

the thing you mention with the rack, is that the bump steer mod ?

[stt]

Do you want me to bring my Digicam tomorrow?

[_SBD16v]

the thing you mention with the rack, is that the bump steer mod ?


yes i am going to be doing somethign very simular to mine once the suspenison have all been set up properly

[Harvey]

What is the bump steer mod and has anyone got any pictures?

[DarrenH]

like this...

http://www.tomstickland.co.uk/astra/mods2/suspension/bumps2.jpg

it moves the inboard mounting points for the track rods up an inch or two on the rack, back to factory positioning. counteracting the nasty track rod angles caused by lowering the car.

[Gander]

Didn't Dr Strickland do the BSM on his 8v and remove it again citing no improvement?

[Brett]

yeah, the arms I refer to are the ones gary made up to counter bump steer. Its got a mounting bracket aexactly loke what odders shows there. the arms also have been 'bent' I dont know why Gary did this, but he says it all worked well. I'll try it and see what happens.

As for progress, at last there is some serious progress to report!!

I did a 16 hour day working on it yesterday, arriving at 8am to paint under the scuttle panel, refit the heater motor, wiper motor and arms and the winscreen washer bottle which is re-located behind there. Ive modded the route the wires for these take so they are all hidden too, coming up through underneath the wiper motor. The original hole for this loom has been fillered and sprayed. I soldered all the connectors back on to the loom and plugged it all in.

Next up craig helped me fit the arb Links, I havent bothered with poly bushes, tbh I dont want a really harsh ride because Somerset have some of the most appaling roads in the country. I used all new links and new rubber bushes, then we torqued it all up to haynes manual recommendations and set the ARB link bushes to the 38mm setting.

Next up the manual rack (massive 4.2 turns lock to lock btw!) which Ive painted up got lobbed on so I could fit the servo. The one Ive used came from a GTE 5dr me stt and I broke about 18 months ago, so had the damper on there. I decided to leave this on as I hate the steering wheel dancing around over bumps and so on like manual racks are prone too, and this should eliminate that at least partially. We had to mod it a bit to make it work with the bump steer modded arms but it all lined up with a few adjustments. I did all that and painted it the other night and so all that was left to do to this was fit it all on, which which wasnt hard as I've taken the column back out. Im thinking about using a non adjustable one because its lighter:D

I took a break from the Astra at this point and helped craig remove the engine from his Corsa SRi, its spun a bottom end shell:(

Simon (stt on here) came over at lunch time to do the brake lines. He'd got all the unions and copper pipe for me as he knew exactly want was needed for it all which made my life much easier. We used bulkhead adapters where the pipes come into the car and also where they go back throught the floorpan at the rear. This took a fair old while, simon made templates to start with before going on and making the brake lines from scratch. I've never seen this done before and bloody hell, its clever stuff!! around the master cylinder looks fabulous with all those fresh copper pipes. Lets hope it works just as well! We used the normal clips for holding the brake lines to the underside of the car to do the same job inside, after craigs mum kindly cleaned them for me!! As you can see from the pics the lines run down the centre of the car, under the gearstick, up over the fuel tank and back underneath the car there. We ran outof copper to do the bottom of the car but Simon wants me to fit the Mk2 Cav Estate rear beam before we do that part. I'll be using goodridge braided hoses instaed of the rubber flexi hoses as per the norm.

Pics from the day... You can see here what else has been done, mainly the loom is nearly all back in now.
http://img158.imageshack.us/img158/228/dscf12119wi.th.jpg (http://img158.imageshack.us/my.php?image=dscf12119wi.jpg)

http://img232.imageshack.us/img232/8172/dscf12106at.th.jpg (http://img232.imageshack.us/my.php?image=dscf12106at.jpg)

http://img232.imageshack.us/img232/8172/dscf12106at.th.jpg (http://img232.imageshack.us/my.php?image=dscf12106at.jpg)

http://img59.imageshack.us/img59/1269/dscf12082kj.th.jpg (http://img59.imageshack.us/my.php?image=dscf12082kj.jpg)

http://img59.imageshack.us/img59/7227/dscf12073he.th.jpg (http://img59.imageshack.us/my.php?image=dscf12073he.jpg)

http://img486.imageshack.us/img486/7835/dscf12065bh.th.jpg (http://img486.imageshack.us/my.php?image=dscf12065bh.jpg)

Last job of the day we attacked a noisey F20 steve had given me to get the speedo sender and ring out of for use in the F28. It didnt want to play ball, so in the ned craig and simon went at it with an angle grinder and got the diff out that way. Steve, I owe you an F20 mate!

I left at about 11.30 PM after tidying the garage!

Yesterday Craig and I went scrapyarding, I needed a seat belt before I could fit the cage. Allarmingly, there were only about 2 Mk2 Astra's accross all the 5 we visited, all said they just crush them now:( Simon had spotted an Renault 19 16v in one of them the day before so we returned and relived it of this...
http://xs72.xs.to/pics/06116/DSCN1879.JPG.xs.jpg (http://xs.to/xs.php?h=xs72&d=06116&f=DSCN1879.JPG)

..... an electric water pump. Pretty useful for a Turbo that will be used pretty hard. Not sure how best to activate it yet, be it tempreture or timer based, but I'll ask those in the know like most things with this car and them implement what I think is best!

After that we went down to Simons farm where he pressed in a new wheel bearing for me. We grabbed his sand blaster and headed back off home. Im going to sand blast me 17's before I spray them, and I like to try most things myself so it seemed like the ideal thing!

Today I was going to do that, but even though I wasnt driniking when I was out last night, Ive had the headache from hell all day and this is the first thing Ive really done all day. I get these quite a lot and its the 3rd consecutive saturday Ive lost to this, its really ****ing annoying but Ive been getting them since I was a kid and theres no simple cure:(

Anyway, this week our attention will turn to the C20LET and F28. Painting, converting and so on ready to fit as soon as we can. Im off to the VBOA sapres day in warwickshire tomorrow with Simon, armed with cash for anything that grabs my attention.

I owe major major thanks to Simon and craig for all their help over the past 2 days, cheers guys I appreciate it loads!

ps. sorry for the long reply. I accidentally deleted this reply once, as I was upploading the water pump picture, so Ive written it twice, you only have to read it once!!!

[rhydgte]

Good stuff

[stt]

see you about 7.30 tomorrow!

[Brett]

am:(

LOL!

[Gteman]

Hat's off to you Brett.

The car is looking feckin great. I can't wait to see it finished never mind you.


Today I was going to do that, but even though I wasnt driniking when I was out last night, Ive had the headache from hell all day and this is the first thing Ive really done all day. I get these quite a lot and its the 3rd consecutive saturday Ive lost to this, its really ****ing annoying but Ive been getting them since I was a kid and theres no simple cure:(


Suffered the same most of my life but i have finally pinned it down to lack of sleep only getting 6 - 7 hours a night. 7 - 8 hours a night no headaches :Banane43:

[stt]

6 - 7hours, im lucky if i get 5!

In all seriousness if you're getting recurrent headaches, get your eyes tested, keep an eye on your diet, if you're not eating enough/ not eating the right food, it can cause headaches.

Simon

[DarrenH]

quality work there dude. i know its only the flash thats making the yellow come out cream, but what a fricken lovely colour it looks on the photos. digress

the leccy water pump, will that be a secondary device, kind of like that fitted to the V6 engines, so that you can circulate water better at idle after caning the car etc ? really good idea that. where you gonna splice it into the circuit ?

[Brett]

Cheers lads, after the last few days I feel so much better about the whole car, progress has been good but money is really really tight right now. I dont even care if its not ready for the end of April, but I do want it done before my birthday in June. I need to start saving money, Ive been trying to give up smoking, with a degree of sucess - Im of the fags at least!

I might sell the Calibra, not what i want to do really as I like it but tbh I want the astra done first and foremost and another £30 hack (Carlton!!) would be fun!

Times also a killer, I would love to work on it 4 nights a week but can only do 2 because of college. I cant afford to keep losing Saturdays like so far this month so I'll sort a doctors appointment this week see what they reckon. I cant miss anymore of college as Im behind from skipping so much last term to do the car anyway!

0dders - Im open to suggestions for the electric water pump. Simon told me the Renault would have one and I didnt need to be told that I should get it and that it would be a really good thing to have, but Im not technically knowlegable enough to know how best to utilise it. It will be a secondary pump, I cant see it being as effiecient as the standard LET pump. As for location, and when best to activate it or how - not a sodding clue right now.

Main tasks for this week have changed slightly. Was going to do the engine but thats now going to wait untill STT has finished with his engine stand as he had kindly offered me the use of his for painting the block and box.

Another peice of good news is COSCASTness!!! I was told by the guy I bought it off it had had a new head at 70k, but I looked for the core plug and coudlnt see one. I was sure this meant a coscast head, I asked Simon and he confirmed it for me:D

Today I made a wasted trip to the VBOA spares day in warwickshire, then after that went to see one of Simons mates with a Mk1 Astra GTE, he'd just built his own MegaSquirt ECU - complicated stuff, but he had it all plugged into his laptop and working - I was so impressed!

This evening Simon and I tried pressing the bushes out of the MK2 Cav rear beam, that didnt work but it got the metal sleeves out and from there me and steve were able to cut the bush out, then cut the sleeve and chisil it out. worked a treat!

off to the pub now, think Ive earned it this weekend!

[CraigGreen]

Today I made a wasted trip to the VBOA spares day in warwickshire

Why was it wasted mate?

[Brett]

because it was complete and utter rubbish, about 10 stalls that was it belive it or not.

Pretty much nothing at all there of any interest!

[Brett]

Strange mirror post of the one in steves thread coming up...

I went to steves today and helped him on his GTE, mainly on the wiring loom, Im good at that now!

I took a break and used steves tools to build up the front legs, stripping the 4 stud astra ones and reassembling in the freshly hammerited Calibra 5 stud legs. The bilstein shocks are much easier to remove that the standard ones, each one was no effort. I reassembled them cleaning the springs and using new top mounts with plenty of grease.

Going to fit them tomorrow so I can drop the front of the car down and remove the 16v rear beam.

[Brett]

Been working on her since lunch time today.

first I swapped on the poly anti roll bar bushes stt gave me. Just the ones for where the wishbone bolts to the bulkhead, not the links. figured poly here probably will five some improvement over rubber without causing any of the other side effects.

Next I cleaned up the callipers ready to paint them. They are from an Mk4 Astra GSi so are fairly new, when I cleaned them up it was obvious they didnt need painting so I set about putting the front legs on. First I had to refit the steering arms. No major problems here. On went the legs followed by the discs. Glad Ive dont the 5 stud conversion now becuase its so much easier to refit a disc thatr hasnt been redrilled, and theres the added bonus of the locating screw lining up!

At this point I noticed there seemed to be an awful lot of play in the wheel bearing we pressed in last saturday. I was a bit worried by this, but I carried on fitting the calliper and finally the wheel. Gave it a shake, theres loads of play, if the car was going to be driven it would be lethal. I soldiered on and did the other side, before trying to jack it up to remove the axel stands.

then the jack broke. by this point I was juct about sick to the back teetj=h of delays and problems. After a few minutes trying to fix it I admitted it was ****ed. I used the engine crane to lift it of the stands and set it back down on the ground.

I then gave the car a shake to have another look at the wheel bearing, this time even with the wheel on the floor it was wobbling all over the place. Either the bearing autovaux supplied is faulty or they supplied the wrong one. There is the possibility that I ordered the wrong bearing for the legs based on the wrong information I suppose.

so with no jack and no one wanting to help anyway I couldnt do anything with the beam. The drivers side leg is going to have to come off all over again and have another new hub. The digi cam then packed in AGAIN when I tried to take some pictures, I got a few but not many.

so, Im feeling pretty fed up about pretty much everything just now. I'm not sure if anything was achieved today! Castle coombe end of this month I can forget about for sure. I'm going to forget getting it ready for any show or whatever, It'll be done when its done and not before then.

At least I wasnt spuing up and having unexplained headaches this weekend:D

pictures of todays efforts! (bit random I know, but as I said camera was playing up!)
http://xs73.xs.to/pics/06120/DSCN1884.JPG.xs.jpg (http://xs.to/xs.php?h=xs73&d=06120&f=DSCN1884.JPG)

308mm discs really fill even the 17's!
http://xs73.xs.to/pics/06120/DSCN1885.JPG.xs.jpg (http://xs.to/xs.php?h=xs73&d=06120&f=DSCN1885.JPG)

ok, yes they are really ****ing large!
http://xs73.xs.to/pics/06120/DSCN1889.JPG.xs.jpg (http://xs.to/xs.php?h=xs73&d=06120&f=DSCN1889.JPG)

yes more brake pictures:D
http://xs73.xs.to/pics/06120/DSCN1888.JPG.xs.jpg (http://xs.to/xs.php?h=xs73&d=06120&f=DSCN1888.JPG)

[Gander]

lol, good to see the crane is coming in handy!
If your stuck for jacks I have a selection of them you can borrow.

[Brett]

just bid on one on ebay joey, need my own!

BTW the ram in the engine crane is on the way out I think, We topped it up last month with haydralic fluid but it was dropping pretty slowly againt today?

Me and steve worked out its done over 14 engine conversions in the last 9 months! Its been majorly majorly handy.

[Gander]

lol, i used it once and now i have to replace the ram :(

[Brett]

its still usable, drops pretty slowly. I'll probably ask everyone who has used it on their car to divide the cost of fixing it mate, wouldnt be fair to give it back like that.

just wondered if it had ever done it to you?

[astrasteve23]

yeah i put a load of oil in it, i have some left so ill chuck the rest in. it drops very slowley tho! i think we all ow joe a drink or 2!

[Brett]

my new jack turned up of Ebay last night, so I headed over to craigs and set about reliving the GTE of its rear beam with Steves help :beer:

Ive now got to weld both the handbrake brackets/and brake pipes brackets to the Mk2 Cav beam, bore out the big holes so I can fit the 5 stud brakes, whichever setup I chose.

We also finally found a working seatbelt for the passengers side, so in went the rear half of the cage at long last.

Will be working on it tomorrow, probably doing the rear beam if possible.

[Harvey]

How's it going Brett, have you got the Cav beam sorted?

[Brett]

I've stripped the anti-roll bar out of it and fitted it to the cav beam, Im going to sort out getting the brackets fitted tonight so I can fit it at the weekend, provided the poly bushes turn up on time! I cant get the poly ones out of the beam that I took of for love nor money!

Have the digi cam back, working and fixed now so I'll be able to pitcture the two beams side by side to highlight the differences.

Been working on the Calibra over the last few days, stripped the bodykit, legs and rear hubs from th Turbo so I can fit it to my 16v, seemed a shame to have all those nice parts fetstering on a garden centre when I could be out posing! Astra's taken a back step for a few days, but I might go and finish the undersealing tonight after fitting the back bumper to the cally.

[CraigGreen]

Sounds like its all happening mate. Good stuff.

Get that LET in!

[Brett]

Ive been really busy mate! been kitting up the cally and Im going to lower it and fit the 5-stud front legs to it saturday so I can run the tubro wheels! fitted the back bumper to it tuesday evening, the rear spoiler to it last night.

Im off to Stt's now to get the rear beam welded up and grab an engine stand so I can start on the LET and F28, and provided my poly bushes turn up I'll refit it on sunday.

no completion date for this now, had no idea how mcuh work all this is, if its ready for Retro in july I'll be happy:D

[CraigGreen]

haha moving the goal posts still !

I will get over to ya for that pump btw.

[Brett]

money sadly mate, still needs a fair bit spent on it and with the summer coming and all the things I'll be doing there wont be a lot of it left for the astra!

so get the calibra sorted out ready for the shows:D

[astrasteve23]

i might be able to do the skirts on the cally on monday night brett.

[Brett]

I think Im in taunton tomorrow night mate with Si doing the rear beam again!

I sold the Calibra Turbo shell yesterday, only asked £100 for it, plus some V6 Calibra rear hubs to convert my cally to 5stud. More money for the Astra, just got to strip all I want out of the turbo shell asap!

[Brett]

just spent the Calibra Turbo money on gaskets and engine mounts. hopefully in the next few weeks I'll be able to sort the engine and get it droped in and bring the car home:D

[Brett]

Today I went to Taunton to see Simon and got the rear beam done, we cut of the brake line and handbrake cable brackets from the old 16v beam and si welded them to the Cav one. I got home and started filing the holes in either end of the beam to enlarge them enough to fit the Vectra rear brakes, this is going to take bloody ages, Ive done half of one side tonight and if I keep that much up for the next few nights I can refit it Thursday.

Havent had anyone bring the engine home for me yet, pain in the arse that is but since the whole car is coming back to mine for various reasons next week I guess it doesnt matter. I'll finish this project at my house during the summer.

[stt]

i need a new welder - mines definately buggered! :(

[GRAK]

Been working on her since lunch time today.

first I swapped on the poly anti roll bar bushes stt gave me. Just the ones for where the wishbone bolts to the bulkhead, not the links. figured poly here probably will five some improvement over rubber without causing any of the other side effects.

Next I cleaned up the callipers ready to paint them. They are from an Mk4 Astra GSi so are fairly new, when I cleaned them up it was obvious they didnt need painting so I set about putting the front legs on. First I had to refit the steering arms. No major problems here. On went the legs followed by the discs. Glad Ive dont the 5 stud conversion now becuase its so much easier to refit a disc thatr hasnt been redrilled, and theres the added bonus of the locating screw lining up!

At this point I noticed there seemed to be an awful lot of play in the wheel bearing we pressed in last saturday. I was a bit worried by this, but I carried on fitting the calliper and finally the wheel. Gave it a shake, theres loads of play, if the car was going to be driven it would be lethal. I soldiered on and did the other side, before trying to jack it up to remove the axel stands.

then the jack broke. by this point I was juct about sick to the back teetj=h of delays and problems. After a few minutes trying to fix it I admitted it was ****ed. I used the engine crane to lift it of the stands and set it back down on the ground.

I then gave the car a shake to have another look at the wheel bearing, this time even with the wheel on the floor it was wobbling all over the place. Either the bearing autovaux supplied is faulty or they supplied the wrong one. There is the possibility that I ordered the wrong bearing for the legs based on the wrong information I suppose.

so with no jack and no one wanting to help anyway I couldnt do anything with the beam. The drivers side leg is going to have to come off all over again and have another new hub. The digi cam then packed in AGAIN when I tried to take some pictures, I got a few but not many.

so, Im feeling pretty fed up about pretty much everything just now. I'm not sure if anything was achieved today! Castle coombe end of this month I can forget about for sure. I'm going to forget getting it ready for any show or whatever, It'll be done when its done and not before then.

At least I wasnt spuing up and having unexplained headaches this weekend:D

pictures of todays efforts! (bit random I know, but as I said camera was playing up!)
http://xs73.xs.to/pics/06120/DSCN1884.JPG.xs.jpg (http://xs.to/xs.php?h=xs73&d=06120&f=DSCN1884.JPG)

308mm discs really fill even the 17's!
http://xs73.xs.to/pics/06120/DSCN1885.JPG.xs.jpg (http://xs.to/xs.php?h=xs73&d=06120&f=DSCN1885.JPG)

ok, yes they are really ****ing large!
http://xs73.xs.to/pics/06120/DSCN1889.JPG.xs.jpg (http://xs.to/xs.php?h=xs73&d=06120&f=DSCN1889.JPG)

yes more brake pictures:D
http://xs73.xs.to/pics/06120/DSCN1888.JPG.xs.jpg (http://xs.to/xs.php?h=xs73&d=06120&f=DSCN1888.JPG)


Hello m8 how are you?
I haven't been on here for a while, so just catching up:wave:

Have you fitted the drive shafts though the hub yet? If not then you will have play in the front wheel bearing as the driveshaft (Or outer CV joint) pulls all the bearing to together.
Cars looking great m8, can't wait to see it in the flesh.
Will you have is ready for the Retro show????

[Harvey]

As Grak has said the bearing will have play in it until you bolt the drive shaft in place and torque it up correctly. Don't loose your faith in the Astra as it'll all come together in time.

[Brett]

more filing done on the beam tonight, its long boring and really hurts the arm, made worse by the fact I havent been able to get the back brakes of the Vectra yet to see how much I have to enlarge them!

I put a shaft in some at the time, it took up the severe play but didnt seem to take it all out. I'll have to wait untill the engines in and then see what its like!

[Brett]

Finally got my MK2 Cavalier Estate beam painted ealier so here are some pictures, showing the difference I know of between it and the Astra 16v beam, I know people have asked in the past!

Main difference is the way the rear shocks mount, clearly much more substantial tham the Astra 16v beam.
http://xs78.xs.to/pics/06175/DSCN1963.JPG.xs.jpg (http://xs.to/xs.php?h=xs78&d=06175&f=DSCN1963.JPG)
http://xs78.xs.to/pics/06175/DSCN1964.JPG.xs.jpg (http://xs.to/xs.php?h=xs78&d=06175&f=DSCN1964.JPG)

I've now managed to get some Cav V6 rear hubs etc from Stt, so when I go down to colect them there will be nothing stopping me putting it back on the pineapple and finishing her brakes at last!

I also did some more to the dash a month or so ago, heres how far Ive got so far...
http://xs78.xs.to/pics/06175/DSCN1965.JPG.xs.jpg (http://xs.to/xs.php?h=xs78&d=06175&f=DSCN1965.JPG)

[Sipo]

Managed to work your way out of the garage then Brett ... all the way to the step :D

Love the dash modifying too, as said before, removing the recess does bring the dash upto date.

P.s, you having any more probs with "you know who" ?? :confused:

[Brett]

Si - I forgot ai told you about that, no everything is completly sorted on that front now so I can rest easy again! Have I stuck pictures up of the dash before LOL!? Yeah to me a MK2 dash looks wierd as standard, the dial binnacle looks so small! the digital guages I have for the extra bit will really go with the digidash!

Ive fitted the ARB and poly bushes to the beam this afternoon, whilst trying to recover from the worlds most raging hangover ever LMAO!

[Sipo]

Good to hear matey! Glad its all sorted, was a little worried for you, was a random outburst! IIRC I think the other pictures of the dash were on your old thread.

Really do have to get round to heading down to see you "cheddar lot" sometime soon.

[Brett]

yeah would be good to see you mate!

I need to get new bolts for the arb through the rear beam, I went ot put them back in tonight and they are a bit to rusty for my liking.

[Black Magic]

is that dash completly made out of body filler? lol? sorry, i mean fibreglass ;) ??

[Brett]

lol no its a standard dash with the heat shrink vinyl covering ripped off mate!

[Brett]

at last!! on my patio, I have some 5 stud rear hubs, allbeit Vectra ones. I'm Going to fit them onto the beam tomorrow night and then the car can come home ands I can get cracking again!!

[GTE16v]

are we going to see this car at Billing Brett?

[Brett]

I doubt it tbh, this 5 stud conversion has been a pain in the arse for some reason, only now I finally have the parts at least. Its been overtaken by money and college - final exams are just over a month away and if my portfolio is done by them too, I will be free again untill september.

At this stage Im planning on taking the Cally to billing with the 17's meant for the astra fitted in order to tart it up a bit!

[Brett]

weel I finally have finished enlarging the holes in the cavalier beam to take the ABS sensors in the back of the Vectra hub. A mate got a super-duper-duper-life-and-arm-saving drill bit and we bored it out in an hour.

Ive been following Mark T's guide on how to fit the Vectra brakes and also had to pm him for some advice. The hubs and back plates are seperated from each other im going to another mates to redrill them on sunday, and then hopefully fit them to the beam and beam to the car.

progress is about to kick off again I hope!

[GazJevs84]

good luck with the progress mate

[Harvey]

:Banane47:

[Brett]

been busy today....

quick pic of the hole in the beam now its been enlarged...

http://xs300.xs.to/xs300/06196/DSCN1969.JPG.xs.jpg (http://xs.to/xs.php?h=xs300&d=06196&f=DSCN1969.JPG)

Went over to a mates and used his pillar drill to redrill the backing plates, as per Mark T's guide I need to reverse them so the handbrake cable is at the top, not the bottom. got home, bolted it all up to check I'd drilled it all correctly, after some filing on 2 of the holes I'd drilled it all when on fine. Took it all apart again and gave it a lick of paint to freshen in all up. The discs and pads are virtually new too!

http://xs200.xs.to/xs200/06196/DSCN1968.JPG.xs.jpg (http://xs.to/xs.php?h=xs200&d=06196&f=DSCN1968.JPG)
http://xs200.xs.to/xs200/06196/DSCN1970.JPG.xs.jpg (http://xs.to/xs.php?h=xs200&d=06196&f=DSCN1970.JPG)

Will take it all over and refit to the car on tuesday night now!

[Brett]

wierd shit, I swear Ive posted this once! must have ****ed it up!!!

I havent been working on the car as have just got back from a traning corse I had to go on in bristol for work today!

Wont be able to work on it for ages now, not till next tuesday! Ive got college tomorrow, The British Sandwich Awards thursday (the oscars of the sandwich world, bow ties and chapagne coolness!) Im staying in london thursday and im off to Gothenburg on friday for a weekend of partying:D Monday its college again and with less than a month to go Im flat out portfolio building.

Proof positive thats I am to busy to work on it! TBH its frustrating, all these things keep getting in the way of the car but I fell they are to good to miss out on!!

I did though manage to sell the remains of the Calibra Turbo I bought for the project on sunday. Being down to 2 cars will be a bit more pressure off too.

from this...
http://xs59.xs.to/pics/05502/BrettCallyT.png.xs.jpg (http://xs.to/xs.php?h=xs59&d=05502&f=BrettCallyT.png)
to this... it was to rotten to be worth saving, especially as the 16v I have has no rust at all, none anywhere! Its unreal!
http://xs100.xs.to/xs100/06202/DSCN1971.JPG.xs.jpg (http://xs.to/xs.php?h=xs100&d=06202&f=DSCN1971.JPG)
http://xs300.xs.to/xs300/06202/DSCN1973.JPG.xs.jpg (http://xs.to/xs.php?h=xs300&d=06202&f=DSCN1973.JPG)
http://xs300.xs.to/xs300/06202/DSCN1974.JPG.xs.jpg (http://xs.to/xs.php?h=xs300&d=06202&f=DSCN1974.JPG)


the body kit is now on the 16v, along with the front legs and lowering springs, brakes and wheels. for £400 its proving to be a total bargin, comfortable motoring for peanuts! All I have left on that is to convert the rear to 5 stud so I can fit the turbo wheels and drop it 40mm. The lad who bought the car is using it to 4x4 his cally V6 so Im having the V6 hubs as part of the deal.

[Brett]

I was hoping to bring the car home this afternoon, but my mate craig whos house it is at came off his motox bike in practice ealier today and was airlifted to hospital with a badly injured leg, gutted for him.

Ive invested in a quaffie ATB LSD :bananajump: :Banane47: for my F28 after saving hard for the last month for sweden and then not spending as much out there as I thought I was going too.

When its home we can really crack on with it, Ive done a fair bit off stuff to it but cant take any pictures because no one is in at craigs for a while now.

[CraigGreen]

Glad to hear the project is grinding along smoothly Brett. Take your time it'll be worth it. I must have a gander again soon. Ive been busy as, of late.

CG

[Kev Read]

Good investment the ATB mate. They are crap without them.

Also the washer on the wishbone! I made the mistake of putting undersized ones on my gold one!

The wishbone was ripped off at about 60mph (during a harsh gear change)causing the wheel to lock up inside the wing (completely destroying it) and bend the anti roll bar!

[Brett]

Is that the front cup ones arpund the bolt head? I got those from vauxhall but the ones that go on the back of the mount with the nut I didnt?

*******s I paid for those too!!

Pleased I was able to get the diff, I wasnt really expecting too be able to afford it! The bloke is recommending I change the driveshaft seals which I will, but is also on about bearings, saying I should get one he has, but I cant replace the 'larger' one because its not avalible anymore? no idea what it means so i have asked him to claify. Its steveboyslim on mig.

[Kev Read]

I think thats who I got mine from. The two drive shaft seals will defently need replacing if you are using a F28. You can get those from vauxhall, cant remember how much. As you will be using the part of the F20 that the seal goes in to order them for a F20 (they are probley the same, but just in case).

He also sold me a bearing spacer thing for £10 which you need to run the F20 ATB in the F28 FWD. As for the bearing itself, order one for a 4x4 cavalier GSi F20. Its the same as the one you need, but for some reason vauxhall cant get it if you ask for a F28 one??:confused: :confused:

Or ignor all of that and ask someone who knows a bit more about it:confused: :confused: :confused: :confused: :confused: :confused: :confused: :confused: :confused: :confused: :confused: :confused: :confused: :confused: :confused:

[Kev Read]

Oh! and as for the big long bolt that holds the wishbone on, just worry about the front that sits up against the bush (bolts head). If the washer is too small it will get pulled through the bush under stress, like mine!

The proper one should cover the whole face of the bush.

[astrasteve23]

Oh! and as for the big long bolt that holds the wishbone on, just worry about the front that sits up against the bush (bolts head). If the washer is too small it will get pulled through the bush under stress, like mine!

The proper one should cover the whole face of the bush.


my van didnt even have any washers there when i got it! put the proper full size ones in.

[Brett]

cheers for that Kev, ties in with what he is saying nicely, the bearing he has offered to supply is the one from the F20, the other he cant supply must be the F28 one. Ive ordered the seals and the bearing too. I'll go into vaux and order up the other bearing from a 4x4 F20.

My wishbones are eactly as yuo describe now, massive washer covers the whole bush. And to think I had an argument with 2 mates about that becuase I wanted the right washer and they said any would do!!!

[Brett]

jesus, Im over £500 less well off now! well worth it though, should make the car a real beast!! cheers for you help there Kev.

Craig - yeah give me a bell sometime and we should meet up, been ages since I last saw you. The car should be home soon, although when depends on how long other craig is in hospital because of his leg. I havent spoken to him yet so Im still pretty worried about him tbh.

[stt]

whats the score with the beam?
My welder is all fixed now so if you drop it down we can move the mounts,
I'm on nights at the mo, text me to sort out when if you want.

Si

[Brett]

need to move the car at the moment mate, craigs going to be in hospital for a while and I need to clear eveything back to mine.

will give you a text shortly mate, cheers!

Diff turned up this morning:D

[Brett]

Im flat out at the moment, had my end of year exams yesterday at college, Im off to France for Le Mans in a few hours:D cant wait.

Anyway, not been too busy with the car, I moved the engine and box home at last on saturday with the help of Gander and his Astravan. Im probably going to get the gearbox done by a local company called Gearchange, they can fit the fiff, FWD converion and the F20 speedo parts. For what Ive spent on the box and diff it makes sense to get it done properly.

Ive also managed to get hold of a 100a altenator and a relacement rear hub from a Vectra after a mysterious disappearnce of some of the handbrake parts!!

[Brett]

Iv spoken to gearchange about the box so it looks like its going there to be done. It'll be the first part of the build I havent done myself or been directly involved in!!

STT is living up to his legendary stauts by offering to trailer it home monday evening after Ive been to college!

Hopefully then I'll be able to do something to it rather than just talk about it....

[stt]

STT is living up to his legendary stauts by offering to trailer it home monday evening after Ive been to college!



You wait til the restoration of STT starts i'll be badgering you to come and help every evening! lol

Just glad i can help mate.

[Brett]

major thanks to Simon last night we A-framed the car home from craigs:D

steve and craig also helped out so cheers to them too.

Its home now. time to crack on as best I can!!!

[CraigGreen]

Thats great news Brett. Hows about a list of things left to do?

[Brett]

Finish Wiring inside
finish dash (needs flocking)
fit front of cage

Clean engine, fit major service parts, oil & water pump, full cambelt kit, lambda sensor, new actuator, adjustable FPR, cleaned injectors, sump gasket. Paint everything too.

Gearbox needs converting to FWD, and having the ATB diff fitted along with the F20 speedo ring and drive.

those are the major jobs. theres still a long way to go but now I can get cracking. Currenly at my last lesson at college untill september:D

[rodg98133]

Looking Good mate

[Brett]

I worked on it today!! (Im not kidding, honest!!!!)

turned back to finishing off the front electrics, this mainly involved wires that need swapping to fit the LET.

First job was to sort out which wires I needed to wire into the 3 little plugs by the LET ECU. this was done last night with the help of a few of the lads of here:beer:

Got to it this morning, fed the loom that runs through the bulkhead back into the engine bay, and set about picking out which wires I needed to move from joining the ECU loom through the round X5 plug to the 3 little plugs back inside the car as mentioned. I established this was the fuel pump black/red, a blue/red and brown/yellow for the fuel computer and the brown/blue for the engine managment light. the other diagnostics wires were hanging from a 2 pin connector found in the loom near the brake light switch, the temp guage blue which comes accross from the main car loom harness in the passenger footwell. I rerouted them through the loom so they all came out in the same place. I then positioned the whole lot to get wire lengths and soldered it all up...

http://xs303.xs.to/xs303/06275/LET3smallplugs.jpg.xs.jpg (http://xs.to/xs.php?h=xs303&d=06275&f=LET3smallplugs.jpg)

footwell is looking much tidyer after all that!

http://xs303.xs.to/xs303/06275/LETwiredup.jpg.xs.jpg (http://xs.to/xs.php?h=xs303&d=06275&f=LETwiredup.jpg)

Now I was bored and wielding a soldering iron.. so I decided yet more loom modifications were needed! I looked at what I could get out of the engine bay, and decided on moving the diagnostics plug itslef into the passenger footwell, and also re-route the outside air tempreture to the front of the car along the same route as the headlight wires now take, conceled behind the passengers wing.

http://xs303.xs.to/xs303/06275/Diagplugreloc.jpg.xs.jpg (http://xs.to/xs.php?h=xs303&d=06275&f=Diagplugreloc.jpg)

this means much less wires in the engine bay!!
http://xs303.xs.to/xs303/06275/bulkheadwires.jpg.xs.jpg (http://xs.to/xs.php?h=xs303&d=06275&f=bulkheadwires.jpg)

havent looked at the round X5 plug yet, it needs the one from the Cally T soldering on and I havent really looked at wireing that up yet!

[Brett]

I havent updated recently, but I have been cracking on with the wiring, which is coming along very nicely!!

I decided, looking back, that I wasnt happy with the way I'd worked the wiring at the back of the car. Only one thing to do then, get the cutters out and remove the whole lot and start again. I elected to rewire everything from the rear wheels back:D the 1.4L I got for free gave up an unmolested bit to solder in. Being a carb model, it dodnt have the fuel pump wires, so I decided to re-route them using nice fresh wire. I soldered it all in, including a new mothod I thought of to get power to the 3rd brake light in the spoiler - utilising the connection pad that removing the rear wiper has left redundant. Its a much better job this time, less joins in the wires. Ive refitted the plastic cover to the boot panel now too.
http://xs104.xs.to/xs104/06322/22072006086.jpg.xs.jpg (http://xs.to/xs.php?h=xs104&d=06322&f=22072006086.jpg)

next up, I looked into what could be done with the wires that come through the bulkhead and into the engine bay just above the clutch pedal. I didnt like this - looks untidy and I'd done so much re-routing that there are only about 9 wires left!! It seemed to make more sense to move them so that they come into the engine bay in the same place as the engine loom. Im going to join the round X5 connector to this and it should then be put of sight behind the inlet manifold.
http://xs104.xs.to/xs104/06322/23072006093.jpg.xs.jpg (http://xs.to/xs.php?h=xs104&d=06322&f=23072006093.jpg)

a little gromit seals up the hole where the loom originally passed through...
http://xs104.xs.to/xs104/06322/22072006085.jpg.xs.jpg (http://xs.to/xs.php?h=xs104&d=06322&f=22072006085.jpg)

with all this going on in the drivers footwell, I looked into moving the bonnet release handle. Moving it to the passengers footwell seemed easy enough, and would mean I could fully hide the cable in the engine bay, which wouldnt have been possible with it left on the driver side. I reversed the mounting to make it all point the right way, then resized the cable. It works perfectly. The cable still runs inside the engine bay, but its out of sight tigh up on the inner wing secured by P clips.

Ive since been going through the loom and making sure all the joins are properly insulated, making sure its all earthed properly and checking for silly mistakes, of which there have been the odd one - I hadnt insulated some permanent lives, what a ***. Made me pararnoid and I did the rest with a fine-tooth combe. I also joined the stereo loom back in, noticed I havent included any wires for the side repeators, hadnt re-wired the fuel pump and hadnt joined the round plug. STT still has to finish the headlight setup and fan override switch, and he'd also going to oversee the fitting of the battery box, coz doing that alone I could well end up frying myself lol!!! That should be done next week hopefully.

The beam is currently being modified so it will fit, I've got to take the brake lines back out and change some of the unions too. Tomorrow night the car loom will be ready to have a test fitting of the dash and components, it wont do to tidy it all up and then find that they wont reach the switches!!

Some of you may also know I bought a quickrak about 18 months ago from RSC Motorsport through Rob_S, well he left and it never turned up - its all a pack of lies and currently in the hands of trading standards trevor's accusing rob of embezzeling money out of the business. Well now another company has managed to pick up the racks which were eventually manufactured and Ive bought my rack again. On a car like this 4.2 turns was so dissapointing I just bit the bullet and paid all over again. Hopefully trading standards may one day recover my money from RSC/Rob/Trevor whoever the real criminal is - I dont know anymore.

more again soon.....

Brett:beer:

[Harvey]

You pit me to shame Brett as all I have done it get the pedal box fitted and put a new car cover on!

[Gander]

Hurry up and finish it mate, I desperately need help getting mine back together:p

[Harvey]

You can't rush an artist at work;)

[Brett]

LOL might try and get up to your tomorrow evening Joey, im at a bit of a loose end!

progress aint fast on this one by a long shot, but with the dash in last night I felt as though a corner had been turned, albeit a small one!!

[Brett]

more pics from tonights efforts -

first job was to put all the dash etc in to make sure the loom was the right length and would sit right. It did mainly which is good news and the modifications I had to make were only small:D Was the first time I'd seen the car with a dash in nearly a year so it felt pretty good!!

http://xs204.xs.to/xs204/06323/09082006125.jpg.xs.jpg (http://xs.to/xs.php?h=xs204&d=06323&f=09082006125.jpg)
http://xs204.xs.to/xs204/06323/09082006126.jpg.xs.jpg (http://xs.to/xs.php?h=xs204&d=06323&f=09082006126.jpg)

wiring all in a pickle. It'll be tidied up only when I know its all correct and working.
http://xs204.xs.to/xs204/06323/09082006130.jpg.xs.jpg (http://xs.to/xs.php?h=xs204&d=06323&f=09082006130.jpg)

few pics of the bonnet release cable move to the passenger side I did the other night too.
http://xs204.xs.to/xs204/06323/09082006131.jpg.xs.jpg (http://xs.to/xs.php?h=xs204&d=06323&f=09082006131.jpg)
cable all hidden from view...
http://xs204.xs.to/xs204/06323/09082006132.jpg.xs.jpg (http://xs.to/xs.php?h=xs204&d=06323&f=09082006132.jpg)

I then took the dash back out and packed it all away again, next time it ll goes in will hopefully be the last time!!

I was planning on attacking it tomorrow night too, but I was driving the Calibra pretty hard up the gorge an hour or so ago and something made a really loud bang as I was going through a fast left hander. Now theres a really loud whine coming from the NSF corner whenever I go round a right hander. Its almost as loud as a gearbox whine - so I'll have to check that out instead:(

Wouldnt have happened in my old GTE 16v:(

[Tom]

That bonnet cable is a brilliant idea :applause:

[Brett]

I cant remember if I removed it from that side when I stripped the car down last year or not - Thats where the idea came from anyway, so Ive no idea if its original!!!

[Kev Read]

Good stuff mate!!

Your wiring puts mine to shame! Never been my strong point.

[Sipo]

Havent checked this for a while, coming along nicely Brett! How long would you say you have left on it? Looks to me like its going to be 2/3 months which will be a c*nt with the weather! Roll on next summer though :)

[Brett]

****ing ages mate!! My target is Le Mans june next year but in reality it shold be well before then. Its going to be another month before this loom is at a point when I can say its finished, as its not tested yet.

plus I went and bought a £500 odd quid laptop last week, that was the LET service bits engine fund originally. Will be playing with it tonight thhough, central locking and engine bay, and at some point stt is going to come down and sort out the battery stuff for me:D

[Brett]

TJ Motorsport have sent me a rocket launcher instead of a quikrak;)

http://xs305.xs.to/xs305/06333/16082006166.jpg.xs.jpg (http://xs.to/xs.php?h=xs305&d=06333&f=16082006166.jpg)

seriously though, im so happy to finally have one after all the ****ing around with RSC. It might have cost me £355 to buy the thing in the end but who cares, Ive got it now. The pursuit of Trevor/RSC goes on though:mad:

another big up for TJM from me!!

[astrasteve23]

what brett said!

[Brett]

Just put a battery on the loom for this first time:D

All went really really well, no major problems to report I dont think:D

It was great to have the windows opening, indicators & hazards going, brake lights tested, heater and wipers and washer jets going!! at fecking last!! Digi Dash even appears to be fully operational:D Its just great, what a boost.

Digi Dash lights my day up:
http://xs105.xs.to/xs105/06340/27082006182.jpg.xs.jpg (http://xs.to/xs.php?h=xs105&d=06340&f=27082006182.jpg)

A list of the parts that havent worked:
Fuse 3 and 6 both Blew. Potential worry here as there has been an incredible amont of p***ing around with the headlight loom- there are relays operating higher power bulbs and changing what ones are on, althought its not finished yet, and I also removed the control box thing that sits behind the dash on the back of the glovebox.... However I think that fuses 4 and 5 would have blown too if there were problems there.

no rear foglights or number plate light, but havent checked the bulbs yet or could be bad earth.

Interior light doesnt come on when opening the drivers door

boot light doesnt come on when opening the boot

[astrasteve23]

cool good to see it working and no smoke/fire!

[Brett]

busy weekend on it for once LMFAO!

started yesterday at lunchtime when I went to get the beam welded by a freind. I had to get the shock mounts moved outwards slightly because the shocks fouled the inner arches when I first fitted it!

cutting of the brackets..
http://xs105.xs.to/xs105/06350/02092006185.jpg.xs.jpg (http://xs.to/xs.php?h=xs105&d=06350&f=02092006185.jpg)

scars left, they didnt want to let go very easily at all!!
http://xs205.xs.to/xs205/06350/02092006187.jpg.xs.jpg (http://xs.to/xs.php?h=xs205&d=06350&f=02092006187.jpg)

simon who was welding it opted to ARC weld it, I hadnt seen this been done before.
http://xs205.xs.to/xs205/06350/02092006190.jpg.xs.jpg (http://xs.to/xs.php?h=xs205&d=06350&f=02092006190.jpg)

filling the hole from gringing it with welds...
http://xs205.xs.to/xs205/06350/02092006192.jpg.xs.jpg (http://xs.to/xs.php?h=xs205&d=06350&f=02092006192.jpg)

youd never know there had ever been anything there by the time he'd finished..
http://xs205.xs.to/xs205/06350/02092006193.jpg.xs.jpg (http://xs.to/xs.php?h=xs205&d=06350&f=02092006193.jpg)

finished article, the mounts were reatached about 10mm further up, they lean the way they do to make sure theres space to tighten a nut onto the bolt when the shocks fitted.
http://xs205.xs.to/xs205/06350/03092006206.jpg.xs.jpg (http://xs.to/xs.php?h=xs205&d=06350&f=03092006206.jpg)

tidy job...
http://xs205.xs.to/xs205/06350/03092006205.jpg.xs.jpg (http://xs.to/xs.php?h=xs205&d=06350&f=03092006205.jpg)

fits fine this time!
http://xs205.xs.to/xs205/06350/03092006200.jpg.xs.jpg (http://xs.to/xs.php?h=xs205&d=06350&f=03092006200.jpg)

fitted it to the car today, there about 5mm of clearance now, when Ive made some slight adjustments to the inner arch (read smack with hammer) it should be 2-3mm more.
http://xs205.xs.to/xs205/06350/03092006198.jpg.xs.jpg (http://xs.to/xs.php?h=xs205&d=06350&f=03092006198.jpg)

while I was at under the rear, I got on with taking the fuel tank of and undersealing the shell..
http://xs205.xs.to/xs205/06350/03092006216.jpg.xs.jpg (http://xs.to/xs.php?h=xs205&d=06350&f=03092006216.jpg)
http://xs205.xs.to/xs205/06350/03092006218.jpg.xs.jpg (http://xs.to/xs.php?h=xs205&d=06350&f=03092006218.jpg)

thats a major bit of the jigsaw pullzle sorted now then, once the beams on i can fit the brakes and finalise the postions of the brake lines. The corner has started to be turned!!

[stt]

looking good mate, Guess I'd better get up to give you a hand with the wiring!

[Gander]

Nice work on the welding there.

Love the pineapple hanging fron the cage!:thumbsup:

[Brett]

simon, yes please mate, then I can give you that money:D I sorted the headlights, it was 2 wires touching and shorting out.

joey - that my pineapple for my pineapple LOL!

[untouchable]

Brilliant stuff Brett :D

[stt]

two weeks without an update! - you're slacking Brett!

[Brett]

Yeah I know, Ive barely touched it, but things have been going on which have taken priority and Ive only had time to paint the fuel tank, fuel pump assembly and rear beam. Need to sort out a few bolts for some bits and peices and then get it all fitted up really, might even get the bolts tonight before college.

[Brett]

been a while (again!) without an update so heres whats been going on in the last month or so!

First up, the tank was fully cleaned up and painted and whilst refitting I renewed all the rubber hoses. Next up was the fuel pumpassembly. I stripped the one from my old car down rather then the one that was on there, I replaced those silly rubber bushes on my old GTE 16v last year and didnt want to do that job again. I took it all apart and painted up the frame, a new filter and new rubber hoses were used and I kept the diaphragm thingy because the one on the Calibra Turbo I broke was virtually new. Refitted it and connected it all up to the tank.
http://xs308.xs.to/xs308/06420/23092006270.jpg.xs.jpg (http://xs.to/xs.php?h=xs308&d=06420&f=23092006270.jpg)
http://xs308.xs.to/xs308/06420/02102006284.jpg.xs.jpg (http://xs.to/xs.php?h=xs308&d=06420&f=02102006284.jpg)

Then the rear beam went back on, followed by the Vectra 5 stud rear brakes which I have fitted using Mark T's guide. I gave it all a good clean first too. Fitted the 5-stud Cally T wheels and dropped t back down. Ive still got to get a torque wrench and torque it all back up though!
http://xs308.xs.to/xs308/06420/22102006318.jpg.xs.jpg (http://xs.to/xs.php?h=xs308&d=06420&f=22102006318.jpg)
http://xs308.xs.to/xs308/06420/22102006320.jpg.xs.jpg (http://xs.to/xs.php?h=xs308&d=06420&f=22102006320.jpg)

Ive started to flock the dash too. With the electrics basically done I can put this back in now, and fit the rest of the cage, seats etc etc. Its coming out pretty well and hopefully shouldnt peel of this time:D
close up
http://xs308.xs.to/xs308/06420/18102006309.jpg.xs.jpg (http://xs.to/xs.php?h=xs308&d=06420&f=18102006309.jpg)
top of the dash done...
http://xs208.xs.to/xs208/06420/21102006315.jpg.xs.jpg (http://xs.to/xs.php?h=xs208&d=06420&f=21102006315.jpg)

Ive also decided to use a different master cylinder. One thing I noticed with the 288mm brake setup I used to have was that fitting them increased the pedal travel before I got any bite, so although I had better brakes they never fel sharp like I really wanted. Swapping rom the GTE m/c to a Calibra Turbo one with a larger piston should mean I can shift the fluid a bit faster and remove the extra travel from the pedal.

Im also about to build up the quik rak and fit that, so the rack I did have has come off to donate some bits and peices. All in all its been a bit of a step backwards for the engine bay LOL!!!
http://xs208.xs.to/xs208/06420/22102006321.jpg.xs.jpg (http://xs.to/xs.php?h=xs208&d=06420&f=22102006321.jpg)

Ive also sold my Calibra 16v to release some time/cash for the project. Ive spent a lot of time and money on the Calibra in the year or so Ive had it and it wasnt making any sense to do so. So as much as I love the car, Ive let it go. Cavalier TD'ness here I come, cheap motoring till the astra's done and then Ive got my eye on an Alfa Romeo 156 when Ive got spare cash again!

[Ian T]

Looking good Brett, long time since I've checked this thread, but I'll have a look back more often now. :)

Starting to think I ought to be prepping my bumpers now...

Ian.

[stt]

Looking great brett, Speak to you soon about the brake lines.

[DarrenH]

like the progress.

those cotton reel bobbin things that hang the fuel pump. that job is probably the most energy and effort outlayed versus the least progresss and satisfaction made, in my entire 7 year ownership, lol.

until i found the plate on the chassis was bayonet fittings. take it to the bench.com!

[Brett]

its an ass of a job isnt it!! The original pump on the car wasnt quite as good only showing early signs of perishing, so Im keeping that incase!!!

why has my motivation returned when the crap weather returns??

Si - need you to come up and finish the headlights & help fit the battery box more than anything else at the moment!

[DarrenH]

what i love especially are the captive nuts on the pump cage, which are bare steel, and the thread on the bolt which is bare metal, with the addition of time provide an impervious join better than a migmate 180, and the fact the big 17mm hex section with which to undo the bobbins and overcome this metalic bond, is about 12 microns thick.

[Brett]

fpmsl at that discription!!! It was the 17mm hex sections rounding of that screwed me right over in the end!

also of buying the bits from Vauxhall, the rubber hanger is £5 each, then youve got to pay about £1 for each nut and 80p for each of the washers.... 3 fekin times!

[DarrenH]

probably right up there in the top 10 poorly designed areas of the mk2 astra. along with the servo mount bolts which you cant undo because the servos in the way.

infact i feel a post in chit chat coming on.

[Brett]

LMFAO - the servo is a doubley (is that a word??) bad one becuase you can be lulled into a flase sense of security with the allen bolts you access by removing the scuttle panel...

.....those buggers are torqued up so hard they just round off LMAO!

edit - just went to look for that post in chit chat! get it done becuase that hasnt been discussed ebfore Im sure!

[Brett]

aye, I want to stay with Vauxhall rims because aftermarket ones always seem to uspet the handling somehow. Kept the ones from my cally T for it:D They will be powdercoated black when the cars done I think.

Went out tonight to have a final go at sorting out niggles with the loom. They were the rear bumper (turned out to be a bad earth which was easily sorted) boot courtesy light (bad earth, still not fixed need to run new earth wire) and the interior light not operating of the drivers door (fixed itself, worked tonight when I tried it LOL!)

So the dash should be goning back in Saturday:D

Also bought a Courtney -02 Actuator and bracket for it today, one came up at a decent price on MIG!

[stt]

The concrete is setting as i type this so you can soon bring it down to mine if you want somewhere warm to work on it!

[Brett]

I'm sure I can remember getting frosty eyelashes when we started fitting my roll cage to the last astra at about 7am on a december morning LMAO!!

I dont think I want it to go down untill its ready to have the engine in, from my point of view its easier to have the car on my drive so i can work on it as and when I get motivation spurts:D

glad the concretes in, how much did you use in the end?

[stt]

about 10 tonnes of aggregrate, and 60 bags of cement!

[Brett]

Just bought a new fuel pump for it, a Walbro GSL392. details here (2nd pump down) if anyone knows what they are looking at as I sure as hell dont, but Im told its ideal for my car:D

http://www.aztpi.com/cgi-bin/store/agora.cgi?product=Fuel_Pump

It also came with a nicely rebuilt bracket assembly, powdercoated and new bushes LOL! For the greater good I have sold the parts I had on the car to someone else needing new bushes!!

[Astraoid]

On the subject of poorly designed areas of the Mk2 Astra - I've always had a fondness for doing the whole Clutch Cable pedal spring thing.

[Brett]

not got that far yet LOL!!

Dash was finished last night up to a standard Im happy with. Fitting scheduled for Staurday LOL!

[Astraoid]

what have you done dash wise then Brett?

[Kev Read]

Looking good mate, I think Im going to copy you wit the dash! It looks cool.

[Ross_Mk2]

On the subject of poorly designed areas of the Mk2 Astra - I've always had a fondness for doing the whole Clutch Cable pedal spring thing.

I hate the clutch cable job!

[PaulGTEturbo]

agreed dash looks the daddio!!!

when is your anticipated completion date then mate, wanna bust a track day with me when its done?

[stt]

clutch cables are easy under a 5 minute job!

admittedly the first 10 or so i did took a hell of a lot longer!

[KEV]

Loving your car mate, that dash idea is brilliant! :)

[Brett]

I'll do some finished pics of the dash tomorrow then. Its not an completely original idea by me, I copied it of a user called cemisis on MIG, although his wasnt flocked like mine.

anticipated completion date? April 2006. Since then Ive learnt not to think of a date, she'll eb done when shes done. April 2007 would be nicelmaolmao

[Ian T]

In time for Retro would be good.

I'd like to see this beast. :)

Ian.

[Brett]

Im really really wanting to take it to Le Mans in early june next year, I love the idea of my 20 year old astra mingling with the Ferraris, Lambo's and Astons in Arnage high street:D So it should be done by retro:D

This weekend is a cracking on with it weekend:D

[Brett]

I think I have some sort of :D smilies addiction.... Has somone put nicotine into them or something?

[Brett]

dash is in and looking good, didnt get as much done as I hoped because of my brothers Astra GSi packing in and it taking most of the weekend to find what was wrong with that.

Picas and full update when my internet at home is working properly!

[Brett]

Internet is back up and working at home now:D

Heres last weekends progress...

started with the car like this... I got a new bolt to replace the shear bolt on the steering colum after changing it and bolted that in properly, then removed all the switches from the loom after giving it one last test.
http://xs109.xs.to/xs109/06470/18112006370.jpg.xs.jpg (http://xs.to/xs.php?h=xs109&d=06470&f=18112006370.jpg)

next up I filled the remaining disused holes in the engine bay through to the interior. Most have been left by rerouting the wires out of sight...
http://xs109.xs.to/xs109/06470/12112006363.jpg.xs.jpg (http://xs.to/xs.php?h=xs109&d=06470&f=12112006363.jpg)
Just the rerouted bonnet release cable left now on the passenger side.
http://xs109.xs.to/xs109/06470/19112006378.jpg.xs.jpg (http://xs.to/xs.php?h=xs109&d=06470&f=19112006378.jpg)

Now I could mount the finidhed dash into the car, I first checked I had all the bits...
http://xs109.xs.to/xs109/06470/18112006369.jpg.xs.jpg (http://xs.to/xs.php?h=xs109&d=06470&f=18112006369.jpg)
then realised I should first fit the boost and AFR guages, doing it with the dash in the car would be nigh on impossible..
http://xs109.xs.to/xs109/06470/18112006371.jpg.xs.jpg (http://xs.to/xs.php?h=xs109&d=06470&f=18112006371.jpg)

Took about 10 mins to fit the dash in. Then I relaised my rerouted bonnet cable plan had come ustuck because now the handle & mount foul the dash...
http://xs109.xs.to/xs109/06470/19112006375.jpg.xs.jpg (http://xs.to/xs.php?h=xs109&d=06470&f=19112006375.jpg)

This made it hacksaw time... Needs tidying with some flocking paint because the blade snapped and I wasnt in the mood to let that stop melmaolmao
http://xs109.xs.to/xs109/06470/19112006379.jpg.xs.jpg (http://xs.to/xs.php?h=xs109&d=06470&f=19112006379.jpg)

Dash is now in and Im very happy with it:D
http://xs109.xs.to/xs109/06470/19112006376.jpg.xs.jpg (http://xs.to/xs.php?h=xs109&d=06470&f=19112006376.jpg)
Is it just me or is this a bit Peugeot 306 like...
http://xs109.xs.to/xs109/06470/19112006382.jpg.xs.jpg (http://xs.to/xs.php?h=xs109&d=06470&f=19112006382.jpg)

Today ive been working on getting the locking right, which still isnt plaing ball:( Befored I go any further I need to get this sorted, and also fit some gauages Ive been waiting for, oil temp and oil pressure. Digital to match the boost and AFR ones I already have. Im gonne put these where the cold air vents are either side of the trip computer.

[mick g]

Good to see you have been busy on the beast. Its coming on:thumbsup:

[Harvey]

Cool stuff. I presume your cage runs in front of the dash?

[Brett]

yeah Harvey, my cgae drops down just in front of the warm air vents so no further dash buchery is required I hope!!

[Dale]

i just read the whole thread start - now Brett, wow loads of hard work has gone into this car. can't wait to read about the engine going in, as i will be doing the same soon. keep the work up!

[Brett]

cheers matey:beer:

[DarrenH]

hey cool! speaking from experience, having the front rool hoops infront of the dash doesnt hinder entering or exiting the vehicle. does mean you have more trouble keying the cage to the bulkhead or indeed the front suspension in future.

cant believe theres still a bit of the original factory red paint work in there !!!

[Sipo]

Great stuff Brett, continual progress which is great :)

[Brett]

hey cool! speaking from experience, having the front rool hoops infront of the dash doesnt hinder entering or exiting the vehicle. does mean you have more trouble keying the cage to the bulkhead or indeed the front suspension in future.

cant believe theres still a bit of the original factory red paint work in there !!!

No it doesnt really hinder a skrawny shrimp like me, even with the door bars in like I had on my old 16v. I hadnt thought but now the dash is in I could crack on and get the cage in too. Needs painting first actually.

Red paint - mmm yeah I was getting a bit low on yellow paint and didnt want to fork out £30 for another tin!! theres still some visable on the underside, which serves as a constant reminder that there still more undersealing to be done....

Oli Pressure and Oil Temp guages Ive been waiting for turned up today, Harvey talked me through the central locking on the phone last night so Im up to speed on that now and can sort that. Ive also bought a swirl pot for £7, this should help prevent fuel starvation - I dont know how they work yet or how it plums in, but for £7 I figured it was worth the punt!!

I've had to take thurs/fri off work this week now for various reasons, but Im hoping Im free Thursday which will give me an extra day to work on the car.

[Harvey]

No probs regarding the c/l, you've got my number now so anymore elec Q's just give me a bell.

[Brett]

Cheers Harvey, thats the last knowm query sorted though.. sure there will be a few more though!!

tonights efforts - make somewere to mount the oil perssure & temp guages. Cold air vents will do nicely:D
http://xs409.xs.to/xs409/06482/28112006393.jpg.xs.jpg (http://xs.to/xs.php?h=xs409&d=06482&f=28112006393.jpg)

[Brett]

I was working on the loom in astrasteve23's GTE yesterday and had a brain wave!

When I lightened my loom, I got petty into it and removed the check control. Of corse, on the Mk2 this contains oil, brake fluid and coolant level warnings. I had to do away with these, not ideal but Ive never ever had one come on in any car I own, so I figured could afford it:D The idea is relocating them into the digi-dash. I gave it a go on my MK2 Cav (I put a digi-dash in the other night and had to do away with the brake fluid light) to see if it would work and was able to do it. The digi-dash even has the right symbol, so after swapping a few pins around in the black plug, I had a fully operational warning light.

I got home and went through the box of wires I kept when i went thropugh the loom last year. Found all the bits I needed, and I've got the loom from my spare 1.4 Mk2 here, so I can rob the pins out of that loom to add into the black plug on the digidash. Only thing is, while the digi dash has the brake fluid symobl, it lacks the right ones fro coolant and oil. Will utlise the saftey belt red warning light for oil (as its red) and probably the choke warning light for the coolant, assuming I cant find away of cutting the correct symbols into the dash.

Its a bit more work, and going back on myself again, but this beast has to be perfect:D

[Addz]

I was working on the loom in astrasteve23's GTE yesterday and had a brain wave!

When I lightened my loom, I got petty into it and removed the check control. Of corse, on the Mk2 this contains oil, brake fluid and coolant level warnings. I had to do away with these, not ideal but Ive never ever had one come on in any car I own, so I figured could afford it:D The idea is relocating them into the digi-dash. I gave it a go on my MK2 Cav (I put a digi-dash in the other night and had to do away with the brake fluid light) to see if it would work and was able to do it. The digi-dash even has the right symbol, so after swapping a few pins around in the black plug, I had a fully operational warning light.

I got home and went through the box of wires I kept when i went thropugh the loom last year. Found all the bits I needed, and I've got the loom from my spare 1.4 Mk2 here, so I can rob the pins out of that loom to add into the black plug on the digidash. Only thing is, while the digi dash has the brake fluid symobl, it lacks the right ones fro coolant and oil. Will utlise the saftey belt red warning light for oil (as its red) and probably the choke warning light for the coolant, assuming I cant find away of cutting the correct symbols into the dash.

Its a bit more work, and going back on myself again, but this beast has to be perfect:D

Thats a really good idea matey! Kinda makes you wonder why it wasnt designed with the warning bulbs on the dash clocks in the first place! Post pics of before, during and after!

[Harvey]

Cut the symbols out the check control and pop them in the LCD dash or use the choke or trailer lights in the LCD dash. There's loads in the LCD that aren;t used so I'm sure you'll figure something out. As before if you need help with the wiring give me a bell as I know what you need.

[Brett]

I think the symbols for the check control might be a bit to big for the digi dash? will try and find my old one lying around tonight.

I think wiring should be stright forward enough, I know the coolant & brake fluid the switch is on the earth side which is the same as the digidash, just no sure about the oil level. Shouldnt be hard to convert though:D

[stt]

If you go to vehiclewiringproducts.co.uk they do symbol sheets

hth

Simon

http://www.vehicle-wiring-products.co.uk/VWPweb2000/switch-1/photo/sym.jpg

[stt]

http://www.vehicle-wiring-products.co.uk/VWPweb2000/switch-1/photo/lenses.jpg