Irmscher kitted OPEL Kadet E van.

[astrasteve23]

1991 Irmscher kitted OPEL Kadett E ‘L’ van.

Colour:

glacier white.


Engine:

2.0 8v
20SEH (130)


to do.

-fit the C25XE and F20 box


Transmission:

Standard F16cr


Suspension:

spax adjustable front shocks,
GAZ adjustable rear shocks.
irmscher -25mm springs,
GTE 16v 22mm front ARB.
GTE 16v aditional rear ARB.
alloy front upper strut brace.


Brakes:

Front: GTE 16v ate calipers with 256mm drilled and grooved discs, OMP fast road pads.
Rear: mk3 astra estate rear beam with mk3 cav SRi disc brake hubs, new drilled and grooved discs and OMP fast road pads.
fluid: DOT 5.1


Wheels:

irmscher 14" alloy wheels with toyo proxy T1-R 195/55R14 tyres


Styling:

full factory fitted irmscher body kit, includes front and rear bumper, side skirts, rear roof top spoiler and the quads are missing. opel badged.
factory fitted roof rack with ladder bars.
GTE bonnet.
GTE doors with all the electrics.
GTE bump strips.
tinted front indicators in front bumper to blend in with black mesh.
mk4 astra smoked side repeaters.

to do.

-fit astra-mk2.com stickers to windows.
-tint the side rear windows and rear door window for security reasons mainly.
-get vinyl for the b pillar


Interior:

GTE black rainbow front seats, re-trimed rear seats in black rainbow trim to match fronts.
GTE black rainbow door cards.
GTE steering wheel.
vauxhall rubber floor mats.
all black plastic interior trim for a merit 3 door estate

to do:

-board out the back


ICE & Security:

kenwood cd player. standard front speakers, kenwood 5” rear speakers.
vauxhall factory fitted alarm.
home made immobiliser


Performance:

standard: 130bhp, 132 lb/ft torque.
k&n filter element
ashley 4 branch manifold

[cielo20]

i see that you have the "to do" in every department except the prformance section :D

[astrasteve23]

lol. i will edit it!

what do you think of it?

[dangte8v]

Looks nice IMO. I have a white gte bonnet and two front wings and two delocked doors if you are interested! And a digi dash and transducer and F16 gearbox...

[astrasteve23]

interested in the bonnet and both front wings if they are mint in glacier white. dont have much money at the moment tho. how much do you want for them? PM me a price please. thanks!

[Tony K]

You've got a rare one there sir, I love it. Room for bass in the back.

Will standard GTE seats fit in the back?

[cielo20]

lol. i will edit it!

what do you think of it?

Looks better now!
I like the van and would be better of with a turbo diesel than the 1.4 it has at the moment so go on with the conversion m8 :D :D :D

[astrasteve23]

im afraid im not putting a big ice install in it. it will be used as a work van. standard seats dont fit. not even standard estate ones. they are different, they are a bit crappy and fold completely flat so its like a van.

[astrasteve23]

in a few months after i have done the sills and other bits i will look out for a free/cheap cav or astra diesel, maybe a crashed one with a good engine. they are very tuneable too!

[dangte8v]

Yep diesel power is the way forward! Larger intercooler, and wind up the low blow LOL! Chipping is such a cheap and effective way of tuning them.

[cielo20]

in a few months after i have done the sills and other bits i will look out for a free/cheap cav or astra diesel, maybe a crashed one with a good engine. they are very tuneable too!

yes they are especially the isuzu engines!!!! we have some that run big boost and nos that run hight 12s low 13s 1/4 mile!!!!! :)

[astrasteve23]

went on here a while ago http://www.diesel-inside.com/forum/index.php
think ill just up the fueling and boost and maybe a chip.
the 82bhp (isuzu) derv is the more powerfull derv, they do a vaux low blow td somethin like 67bhp.

[astrasteve23]

i got the van on sunday 4/9/05.

on monday i decided to take a look at the rear brakes as they were sticking and they failed the MOT. i eventually got the drums off after about half an hour! lol. the most brake dust i have ever seen in a drum before! shoes were down to the rivits, nothing mooved not even the handbrake, everything was completely seized! took the cylinders out and that was about it. tuesday got new shoes, cylinders, rear hoses and a metal exhaust hanger for the back box as it had snapped. i fitted the hanger last night.

wednesday night i took the shoes out and cleaned the back plate up and greased the h/brake cable. new shoes were the wrong ones. also took a side skirt off and so i can fit GTE ones for the MOT to cover the very bad sills up as the irmscher ones dont cover them completely. this is only tempory as i cant afford to get the sills done at the mo. gonna get both sills and rear arches and the bit behind the rear bumper on the sides done when i get the money to. needs a patch in each arch front and rear for the MOT. started preping them tonight ready for my mate to weld some paltes in.

[James C]

was wondering about the german full stainless exhaust that u mentioned in your performance "to do list"?

how much, and r u able to get 4 the 5dr sv??

i'm after some sensibly priced noise!

[astrasteve23]

ill have a look for you.

[astrasteve23]

was wondering about the german full stainless exhaust that u mentioned in your performance "to do list"?

how much, and r u able to get 4 the 5dr sv??

i'm after some sensibly priced noise!


id recoment an ashley mild steel 4-2-1 manifold and full system for your car mate! about £200ish for the lot!

[astrasteve23]

got the correct shoes in the end, put new cylinders in, just gotta change the rear hoses now and get the welding done a put GTE skirts on it tempory for the MOT as they cover the complete sill and i cant afford to get them done at the mo. was quoted £300 to do both sills and rear arches! i supply pannels (£30ish) thought that was quite cheap. will do it when i get the money.

[md28]

Excellent, love it mate, so rare!

I shall follow this thread with interest! :D

[Defiance]

Hiya's,
Had the pleasure of seeing it in da flesh
Very smart
Gonna be fantastic when this guys finished with it ;)

Have Fun

Adios

Def

[James C]

id recoment an ashley mild steel 4-2-1 manifold and full system for your car mate! about £200ish for the lot!

i was thinking about gettin a sportex full sys for £130. however there have been posts on the side about the non lastingness of the mid section.

didn't even really want to spend £130 really, may just have to get a cheap and cheerful back box!

read Tom stricklands astra guide too, was put off getting a 4branch manifold when reading. did u have one on ur 1.4??

did u have a webber carb too?

i've been looking about and haven't managed to find a place that stock any for the astra, or do u just get the carb, plus the relevant bracket/manifold and set the jets according to engine??

thanks buddy

[astrasteve23]

i didnt have a 4-1 manifold or webber but i would of put them on if i was keeping it. i am after a webber for my new 1400 van. they do them as a direct replacment i have heard. put up a wanted post on mig and you will probably find one. i know a few people with 1400 nova's that have put an ashley 4-1 and has made a lot of difference.

[astrasteve23]

fitted GTE 16v 256mm front brakes on it tonight with drilled and grooved discs. gotta do the clutch next.

[Heathercdi]

also took a side skirt off and so i can fit GTE ones for the MOT to cover the very bad sills up as the irmscher ones dont cover them completely.


be careful with doing that mate as they can remove the sideskirt to check the sills, if they are covered.

[astrasteve23]

be careful with doing that mate as they can remove the sideskirt to check the sills, if they are covered.

i thought that they are not allowed to move the skirts to check. i done it to the mk2 i was running around in a while ago and it went straight through. they are quite good where i take them for MOT. not too fussy

[Heathercdi]

i thought that they are not allowed to move the skirts to check. i done it to the mk2 i was running around in a while ago and it went straight through. they are quite good where i take them for MOT. not too fussy

They are allowed to remove the skirts to check the sills (although they would probably just pull the top of the skirt away from the car body) because as you probably know the sills are structural to the car. If you can get away with it then great but just a prewarning incase they do fail it.

[astrasteve23]

i dont think they will look as i know the guy and my dad who used to be in the trade has known him for years and they are good with their MOT's! i was told that if the skirt is fixed on they aren't allowed to take them off. they wont be able to get them off very well anyway the way i am going to fix them! we'll see what happens. hopfully get the welding done early next week and then MOT!

[astrasteve23]

had it welded today by the guy that bought my scrap mini, done a deal. carb is playing up real bad gotta whip it off and check the choke is ok as it is one of the weak points of the crappy pierburg carb! also ordered new track rod ends. hopfully will be on the road next week.

[astrasteve23]

i took the carb off and cleaned it and re-fitted it on sunday and set it up and now seems to be running ok.
discovered that the fuse for the interior light, sterio etc. and hazards had melted to the fuse box! the guy that welded it didnt disconnect the battery and it has caused a power surge! gotta check the loom and because it has also melted a fuse terminal away i have to take all the wires out of that fuse and put an in-line one in! hopfully no loom is damaged.

[astrasteve23]

brett came over today, sorted out the fuse, fitted GTE side skirts. so it ready for MOT now! finally! i also picked up some black GTE front and rear seats for it yesterday.
fitted track rod ends on thurs night, that was fun, never had them not want to come out before and pull the ball out of the joint! got new ones fitted in the end.

[astrasteve23]

fitted new timing belt and fan belt.

MOT is booked for thursday!

[astrasteve23]

van failed MOT today!

inproper repair on n/s & o/s sill

rear brakes low

co high

[Brett]

also had rust within 30cm of a suspension point in 2 places didnt it?

[astrasteve23]

yeah i think that was the sills, i have to go in and check tomorrow cos there isn't any other rust threre!

[Gander]

to do.

-get a webber 32/34 DTML carb.

I've got one if your interested Steve:)

[astrasteve23]

new sills and arches are being done in 2 weeks.

black GTE seats going in after welding is done and mother is re-trimming rear seats next week. got all the material off of the GTE rear seats ready to do it.

[astrasteve23]

the van went to my mates bodyshop yesterday, i took the front wings and rear bumper off, its having the sills and rear arches replaced, getting the smooth scuttle pannel sprayed, quads sprayed, and the rear bumper has been split and that is getting repaired.

[Jon S]

got the solid top mounts on yet?

[astrasteve23]

got the solid top mounts on yet?

? they aren't for the van, they are to go on the GTE when i start working on it again.

[astrasteve23]

got the van back from the bodyshop today, was ment to have the sills and rear arches done. the bloke is flat out with work and has just put the 2 new sills on, im gonna take it back for him to do the rear arches and spray the quads and smoothe scuttle and do a repair to the rear bumper where it has been hit.

gotta put the engine in out of my old 5 door this weekend then it should be ready for re-test.

on friday night i am picking up some white GTE doors and a GTE bonnet from someone near me who is breaking his 8v. will pop to the scrappy sometime and get a c/l e/w e/m loom from an estate and fit so i got all the electrics. could nick the loom from my GTE project car but i dont think the loom to the rear door will reach.

[astrasteve23]

got the engine out of the van today and the other one in, just gotta connect linkage, shafts and rad now.
i also fitted a 22mm GTE front arb to it.

[GazJevs84]

good work dude any pics?

[astrasteve23]

didnt get any pics of the swap, its the same size engine as before. i will get some better pics of the van on the weekend when i can take them in daylight.

[astrasteve23]

i gave the bay a bit of a clean tonight and re-fitted the rad, connected all water hoses and fuel pipes, fitted new choke cable, cleaned header bottle out, connected throttle and clutch cable, just got to do gear linkage, exhaust, and tighten all mounts, fill up water and gearbox oil and connect battery!

[GazJevs84]

good work dude keep it up mate

[astrasteve23]

list of things still left to do:

fit doors hopfully this weekend.
get and fit c/l, e/w, e/m loom.
get some black GTE door cards for it.
get some decent merit spec front wings for it.
get a digi dash for it.
get a GTE 16v rear arb.
might get a GTE non abs servo and master cylinder for it.
get rear arches done, smoothe scuttle and quads sprayed and fitted in new year.

[astrasteve23]

got the engine running tonight, all running spot on! linkage is ok, clutch is fine. pretty chuffed. also tightened up the arb link bars, bottom ball joints, connected exhaust etc and took it for a little drive. the tracking is very bad, something i haven't got round to doing yet, hopfully have a go at it on the weekend. do it by eye and how it drives for now.

[GazJevs84]

good stuff glad to hear it is running

[astrasteve23]

van passed the MOT today!!!!! finally! it will be on the road on thursday.

[BazW]

looking forward to next years shows, gonna have a good mix of stuff with the projects that are ongoing at the moment :cool:

the post mot feeling's great when you've passed for another year :D

[GazJevs84]

good to hear it mate

[astrasteve23]

the van still needs a good polish, when the rear arches get done after christmas the bodyshop will polished the outside for me for a bit extra, the quads and smooth scuttle will be done too.

i sorted the tracking on monday night, done it by eye and how it feels turning and it all seems ok.

[richie00boy]

Cool Steve. Shame you aren't going to the Christmas meal. Hopefully you can make the Salisbury meet in the new(ish) year :)

[astrasteve23]

yeah i should be able to get to the meet and will be at billing and retro next year and possibly others.

[richie00boy]

Will have to slinky down to Cheddar myself as well when the weather brightens up.

[astrasteve23]

let me know when you are coming to cheddar, the gorge is just as fun in the wet, went up there in the van on my lunch break, it doesn't handle too well, needs to be a bit more oversteery and i need to get the tracking sorted properly to help turn in.

[richie00boy]

I'm too frightened to have a go in the wet! I can't afford to lose this car!

[Brett]

New surface in the gorge gets the thumbs up from me:D far better than before, cant wait to try and take a quick car up there!!

[astrasteve23]

the carlton gripped better now its been re-surfaced which wasn't as fun. i want to drive kev's cossie up there!!!!

[Brett]

youy back bumper is loose steve, it was flapping around as I followed you back from mine ealier LMFAO!

drivers side it is LOL!

[astrasteve23]

yeah i know, where it fixes on the side has rusted away, i will try and sort it some how on sunday until i get the arches done.

[astrasteve23]

sorted the back bumper for now. exhaust started blowing 3 days ago, it had split on the front section where it joins the centre section and was getting louder and earlier on when i was racing my mate craig down the lanes in his corsa 1.4 SRi when i changed to 3rd it came apart and is stupidly loud as the front section is hanging down so it has no silencers! in the process of getting a full stainless system for it from germany. will put the front section off of my old car on it on the weekend. im getting a lift to work tomorrow because i will only get busted for it.

i have fitted the GTE seats in the front and got a centre consol for it as it didnt have the bit that surrounds the handbrake.

i am happy with it tho, it stops very well and handles well and goes allright, its a touch slower than craigs corsa 1.4 8v mpi (82bhp) SRi, goes round corners about the same and his is lowered 60mm which is too low really and it bounces about a lot. my brakes are better, it was a very good race earlier.

[GazJevs84]

gdgd shame to hear about the exhaust hope you get it sorted soon mate

[astrasteve23]

went to scrappy this morn and got a front pipe free, went to fit it and the centre section is so rusty the front had rusted to it so i couldn't be arsed tryin to get it out so got brand new front and centre section for £25inc. vat. will fit it in the morning.

[Brett]

LMFAO its so loud its deafening!

the dead in steves local church have been complaining about a lack of sleep!

[GazJevs84]

the dead in steves local church have been complaining about a lack of sleep!

funny as fook some cars round here are like that

[astrasteve23]

was supplied with a hatch centre section so driving it with no back box tomorrow, hopfully will have right part tomorrow. at least it has 1 silencer now, it sounds quite nice actually!

[astrasteve23]

got the right centre section yesterday and it is all fixed and quiet again.


also got some irmscher quads from sipo, they need to be sprayed white and all the lamps are crap so i have 3 brand new ones on the way that i got cheap on ebay, just need one more.

[astrasteve23]

a few pics taken today up cheddar gorge. http://www.astra-mk2.com/forum/showthread.php?p=37227#post37227
i am hopfully getting some smoked rear lights from germany for it, and need some GTE front wings, and i am on the lookout for a SRi or LXi bootlid for it.

[astrasteve23]

i didnt win the smoked rear lights on ebay, computer crashed, was well pissed off!

the ignition switch burnt out on the way home from work yesterday, fitted another that i had spare, also fixed the rear wiper last night, wire going into boot had broken. also adjusted up the rar brakes, it started to have quite a pedal travel since the rally last week. all ok now tho.

[GazJevs84]

good stuff

shame about the lights

[astrasteve23]

mother has finally started to re-trim the rear seats, bottom part that you sit on is done, back part should be done tomorrow, not a perfect job but good enough, looks better than the old grey specled shite! will get some pics up when they are fitted.

[astrasteve23]

finally finnished the seats and fitted them today, they look quite good, will get some pics in the week.

[Tony K]

Picture, Pictures, Pictures!

[DarrenH]

damn those pesky MOT inspectors trying to enforce laws lol !!! i find metal has much better strutural properties than gte sideskirts anyway ;)

projects is ocming along cool :)

[Brett]

lmao half the old sill is stll stuck to the back of the GTE skirts from where we had to take them off after it failed.

I thought it was pushing it a bit at the time tbh, the sills were f*cked!

[astrasteve23]

lol. they didnt really have much to stick too and one part kinda fell off!

will take some pics on the weekend.

[astrasteve23]

must take some pics of the rear seats soon, still haven't taken any.

been having a few problems lately with the van, its been understeering on full lock at low speed (under 10mph) badly and the wheels have been draging where the castor angle is out, it has done it since i got it. was getting ****ed off with it so i got some standard struts to go on the front, swapped the 5000mile old wishbones from my old car onto it, and a 500 mile steering rack, still no difference. also i have done the tracking recently.

thought about and had a chad with me dad and i remember that when i done the tracking that i couldn't adjust one of the tre's as i over tightened the pinch bolt and snapped the head off, so i put a new tre on it (had to take the arm off and cut the bolt)
i then found the centre of the rack (didnt do this when i done the tracking before) and put the steering wheel on straight, took for a drive and when i was at the centre of the rack (should of been straight) i was pulling to the right, so i adjusted both sides about the same amount each until it drove straight, now the steering is so much lighter and more responsive and i only have a slight bit of scrub on full left lock, hopefully this will be sorted when i do the tracking again when i go to my g/f's dads place and use his guages.

also fitted an upper front strut brace from my old car after i messed about with the tracking.

im on the look out for a pair of GTE front wings in white, gotta be in good nick, and black door cards in origional condition.

haven't had chance to corner it properly yet as i have had it loaded up with tools.

[GTE16v]

im on the look out for a pair of GTE front wings in white, gotta be in good nick, and black door cards in origional condition.



PM Mel (Untouchable)
.

[astrasteve23]

ok thanks.

[astrasteve23]

been doing a bit of work on the van lately, fixed the anoying broken washer jets, and started to t-cut it to see if the paint would come back to life! i done half the bonnet twice and it has come up nice, not perfect tho so i went to a local bodyshop that my mate runs and asked what polishing compound he uses and got a quote on getting the rear arches done and a few other bits. found out that he uses G3 polishing compound so im gonna get a bottle of that and get a mop for the polisher that dad has and go over the whole van.

He quoted £150 a side for rear arches, and £100 for spraying the quads, smoothe scuttle pannel, door handles, boot handle, and repairing a cracked bit on the rear bumper. so £400 all in. might also get a belmont or mk3 astra fuel filler flap welded on at the same time just to finnidh it off.

Tonight brett came over and we fitted a 16v rear external arb that he gave me, it fitted straight on, wholes were allready there.
tightened the rear wheel bearings.
we had fun trying to get the new vauxhall lockers off, that are highly rated. when i got my wheels balanced i forgot to change the setting on the airgun to the lowest setting to put the bolts back in and they were so tight that the socket slipped off and rounded the pattern in the bolt! so i took the raer lockers off incase we messed up the socket trying to get the front ones out, got the big bar and hammered it to shock it and drivers side came out, but the n/s one that slipped wouldn't come out, so we went for a drive round the lanes to heat the brakes up to see if the hub would expand and help lossen the bolt! and it worked!!! was pleased that it did because i couldn't be bothered to sit there with a drill all night! lol.
got a bit done on it anyway.

[astrasteve23]

got another quote for the rear arches from a bodyshop down the road that has been recomended by a few people, he quoted £150 a side for the arches and extra £150 for the other bits so was £50 more than my mate.

gonna get another quote from my half brother who does real good work, he does a lot of turreting on rally cars etc aswell so might have a chat about turreting the rear of my 16v!

[astrasteve23]

me half brother quoted £150 a side but said he doesn't have a sprayer at the mo. i have decided on my mate doin it. its goin in on monday, new rear arches, lower rear quaters, repair on rear bumper, spray quads, scuttle, and door and boot handles. he also got me some G3 compound and a G.mop that i am gonna do the van with to bring the paint back to life! should look good at retro! i have new red opel stickers for the bonnet and boot, new pinstripe for the bumpers, and astra-mk2.com stickers to go on aswell.
i might not have the quads in tho as i need 4 new lamps for them and cant arord them at the mo! :(

[astrasteve23]

the van has gone in to my mate to have all the work done, i have also polished it all up with G3 compound with the polisher, paint has come up ok.

[astrasteve23]

the van came back at 9pm on friday night, was a mad rush to get it up together in time for retro, i fitted front wings with new mk4 astra side repeaters on friday night, on saturday i took front seats out and fitted c/l, e/w, e/m loom and fitted GTE doors, fitted colour coded door handles, new locks, GTE door cards and cleaned inside and re-fitted seats. also finnished polishing and waxing it.

here is a piccy of it at retro today, the cleanest it has ever been!


http://xs.to/xs.php?f=P7020436.JPG&h=xs102&d=06260

[Harvey]

I looks a cracking project Steve and I loved the Irmsher kit on...a van. Was good to meet you today.

[astrasteve23]

yeah still got a bit more to do, im happy with it tho, the doors and bonnet that were off of another car dont quite match so i will replace them with matching ones one day. cheers for the good coments. was good to meet you too. cant wait to see your other projects! are you gonna be at billing?

[Pete]

Loved the van today! i didn't think it was a factory job, have you ever seen another like it?

[astrasteve23]

yeah it is all irmscher factory fitted stuff, i have never seen that kit on an estate/van before in the uk, i seen one on german ebay and the rear bumper went for £90 and roof spoiler went for £40! i have seen the kit on a hatch before, i think there a few people on the forum with irmscher kitted cars. they done a few different style ones including a wide arch version of mine for the hatch.

http://jpf.webzdarma.cz/Irmscher.html

[astrasteve23]

if anyone took any pics of my van can you put them up in this thread or send them to me please.

[Gteman]

Loved your van Steve. Sorry I didn't get a chance to meet you, I think the heat knocked the wind out of most peoples sails.

[Kris]

This is the only one i got of youre van Steve

http://img.photobucket.com/albums/v311/K8CEE/DSCN0305.jpg

[astrasteve23]

been doing some work on the van today, fitted origional steering rack back on it as the so called re-con one that hadn't done many miles was shit, had play in it and was leaking, at the same time i fitted an adjustable steering column so now i have a complete lock set that uses the same key. also replaced the tatty 16v steering wheel with a mint one.
brett popped over this evening and fitted a 16v digi dash for me, soldered all the wires up etc, had to make a loom and connector for the transducer as i wasn't supplyed the connector plug for it, all worked fine first time! big thanks to brett, really chuffed looks real good! it has the blue filters in it. on the list for tomorrow is to pop to the scrappy and get a rear GTE bump strip for drivers side which is missing get the tracking done and also fit some GAZ gas adjustable rear shocks that i ordered up from rally design 2 weeks ago, they had to be specially made and they said they would be at least 4 weeks, they arrived in 2 weeks, they look really good quality, cost £110 posted. got to save up for some bilsteins (£100 ish posted) or GAZ adjustables (£150 ish posted) for the front now.
i am showing it at a local car show on sunday so have got to polish it up on saturday.
also got to get the rear windows tinted soon and fit vinyl to the b pillar.

[Ross_Mk2]

This is the only one i got of youre van Steve

http://img.photobucket.com/albums/v311/K8CEE/DSCN0305.jpg

Just an out of the blue question: whos is that spankingly blue looking asta behind steves van? Have you more pics of it?

[Brett]

Valver's motor I think Ross.

Glad you happy with the dash, cant belive it all worked first time, no flames shocks or sparks:D

[astrasteve23]

another update. poped to a tyre place that a bloke down the road (who drives an astra GTE 16v) works at to get the tracking done properly, was done with there 4 wheel laser gear and is now spot on and cost me just under £13 trade price :) then they weren't busy so they let me use the ramp and fit the rear shocks, bit awkward but went ok, the van drives really nice now, its a lot better off the line too because the back doesn't dip causing the front to lift and wheel spin. oh and the digi dash is bang on accurate @ 70mph which is good.

off to the scrappy in a bit to get a rear bump strip. then get the plastics around the dash put back on.

[astravanmk2]

Steve are those manta wheels?

[astrasteve23]

yeah manta GTE wheels, et30 offset, drives fine tho now the tracking is done. steering is just slightly heavier than it is with standard vaux et49 wheels.

plastics are fitted back on the steering column and bump strip is on. just going to clean the inside in a bit then that'll do for today.

tomorrow i will give it a polish, i also have to fit rear lower arms/hubs on bretts cally ready for the local motorshow on sunday.

[astrasteve23]

just some pics of the GTE front seats and re-trimmed rear seats

http://xs305.xs.to/xs305/06334/seats.jpg.xs.jpg (http://xs.to/xs.php?h=xs305&d=06334&f=seats.jpg)

http://xs305.xs.to/xs305/06334/P3250366.JPG.xs.jpg (http://xs.to/xs.php?h=xs305&d=06334&f=P3250366.JPG)

http://xs305.xs.to/xs305/06334/P3250365.JPG.xs.jpg (http://xs.to/xs.php?h=xs305&d=06334&f=P3250365.JPG)

[astrasteve23]

a pic of digi dash and new GAZ adjustable rear shocks.

http://xs305.xs.to/xs305/06334/digi.jpg.xs.jpg (http://xs.to/xs.php?h=xs305&d=06334&f=digi.jpg)

http://xs305.xs.to/xs305/06334/P8170004.JPG.xs.jpg (http://xs.to/xs.php?h=xs305&d=06334&f=P8170004.JPG)

[astrasteve23]

some pics i took of the van last night.

http://www.astra-mk2.com/forum/showthread.php?t=8250

[astrasteve23]

finally got a petrol tank from stt to go on it as it started to leak ages ago but has recently got a lot worse, its going into bodyshop to be waxoiled soon so ill take the tank off, get it waxoiled and then fit new tank.

[DarrenH]

vans looking great, top work all round.

was that matts steering rack that was shagged ? if so i genuinely apologise on his behalf, or rather on the behalf of partco. it was only a few months old and had done no miles.

[astrasteve23]

cheers. yeah it was that one. is was nackered when i fitted it. allways had play in it. the origional is back on and tracking is spot on now and it drives/handles lovely now!

just got to get the lamps for the quads and get them fitted.

[astrasteve23]

i have purchased a 20SEH for the van and also an ashley 4-2-1 manifold to go on it. will fit that within the next couple of months.

[astrasteve23]

i went and took the 20SEH out of the cav on the weekend, gonna clean it up and paint the block before i fit it, i will be putting in new 8mm fuel lines and pipes to suit engine, mine are 6mm at the mo, will ensure good fuel pressure as well as mine are old and probably leak or draw in air. cant wait to get it fitted!

[astrasteve23]

also purchased a k&n pannel filter for it and i am going to scrappy at weekend and getting oil cooler and oil pressure switch from a GTE 8v to be fitted as well.

[MK2-JOHN]

sounds good Steve, gonna be a quick van when its finished

[astravanmk2]

Excellent work keep it coming

[astrasteve23]

yeah will have a bit of poke!

[astrasteve23]

for christmas i got a new cd player for the van as mine has been broken for about 8 months and some custom number plates and with money i got from christmas i got some genuine irmscher 15" et 28 wheels which are part of the irmscher kit that it has. i bought these on boxing day from rabbit off of mk2cav.com (thank brett for meeting him to collect them) for a very good price and i fitted them today. i am going to fit the plates tomorrow or friday and give it a wash and get some pics up. just got to get new lamps for the quads and get them fitted.

[Brett]

wheels are the finishing touch, and was good to have a chat with the MK2cav.com bloke about crusty cavs for once instead of crusty astra's!!

[astrasteve23]

i gave the van a wash and fitted the new plates today.
http://xs310.xs.to/xs310/06526/PC300427.JPG.xs.jpg (http://xs.to/xs.php?h=xs310&d=06526&f=PC300427.JPG)http://xs310.xs.to/xs310/06526/PC300429.JPG.xs.jpg (http://xs.to/xs.php?h=xs310&d=06526&f=PC300429.JPG)http://xs310.xs.to/xs310/06526/PC300425.JPG.xs.jpg (http://xs.to/xs.php?h=xs310&d=06526&f=PC300425.JPG)
http://xs310.xs.to/xs310/06526/PC300426.JPG.xs.jpg (http://xs.to/xs.php?h=xs310&d=06526&f=PC300426.JPG)http://xs310.xs.to/xs310/06526/PC300428.JPG.xs.jpg (http://xs.to/xs.php?h=xs310&d=06526&f=PC300428.JPG)

[bencooperis21]

looks nice mate you takeing it to an show's next year ??
the back looks like it has been lower or some thing but the front looks like a big gap
have you lowered it ??

[astrasteve23]

yeah it will be at the shows again, i went to retro and billing this year, prob do pvs, retro, and billing next year.
the rear is lowered 25mm but the front is standard at the mo as i had nackered wheel bearings and just swapped legs. i will put the springs into the big block (GTE) legs and get some uprated front shocks ready for when i fit the 20SEH.

[bencooperis21]

to lower the back did you use springs from a car ? or estate one's ??

[astrasteve23]

they were all ready on it, they are irmscher so i expect they are estate ones.

[bencooperis21]

ok as some one said to me you cant fit back springs to a estate from a car but my back one's i got from oddball when right on

steve cant wait to see your van at the show's next year

[astrasteve23]

they would fit as they mount the same, just might give different ride height than on hatch and also wrong spring rate.
have you driven it with them on? what is it like?

[bencooperis21]

goes like it is on rails sticks to the road like glue and they are off a gte and they are 35mm springs

[Dale]

how come you want to fix 20seh rather then 20xe?

[astrasteve23]

beacuse i got it cheap. its only 20bhp less than a XE, it'll be quick enough for a work van. nice simple engine too.

[MK2-JOHN]

Van is looking really nice now Steve, Those Irmscher alloys really set it off:applause: :thumbsup:

[astrasteve23]

cheers. there are a few niggley things that have to be sorted, couple chips on rear bumper, petrol cap and boot handle to get sprayed, extend and paint smooth scuttle pannel, fix central locking.

[astrasteve23]

i have cleaned up the SEH i have and have primered it, i am gonna paint it up so it looks fresh and i will be able to open my bonnet at the shows! the whole of the 1400 is caked in dirt and oil.

[astrasteve23]

just a few pics of the engine when i got it and how it is now.

part way through cleaning it up.
http://xs512.xs.to/xs512/07072/PC050351.JPG (http://xs.to)
primer.
http://xs512.xs.to/xs512/07072/P1310201.JPG (http://xs.to)
primer.
http://xs512.xs.to/xs512/07072/P1310202.JPG (http://xs.to)
painted up.
http://xs512.xs.to/xs512/07072/P2120231.JPG (http://xs.to)
http://xs512.xs.to/xs512/07072/P2120232.JPG (http://xs.to)
http://xs512.xs.to/xs512/07072/P2120233.JPG (http://xs.to)

all i have left to do is paint the cam cover white and re-fit front engine mount and oil dipstick holder.

[GazJevs84]

Looks smart that fella :grinning-smiley-043

[astrasteve23]

just have to fit it now and service it.

[Ross_Mk2]

Thats nice that is mate, done a real good job of that!

What was it painted with?

[Tony K]

all i have left to do is re-fit oil dipstick holder.

Is there a gasket to replace with this? Need to clean mine up.

[astrasteve23]

i cleaned it up with petrol and wire brushes in a drill, then air lined any dust off and pannel wiped it. i primered the lot with an etch primer then sprayed the gearbox and head etc with 5 wheel silver (2 coats) then done the block with red engine paint (2 coats) and the mounts, dip stick holder etc i done in black spray on hammerite (2 coats) and the dip stick is done with the red engine paint.

i dont think the dip stick holder had a gasket when it came off.

[astravanmk2]

Hi mate van looking mint, i hope to get mine to billing this year never will it be as mint as that tho lol

[astrasteve23]

Is there a gasket to replace with this? Need to clean mine up.

i re-fitted the dip stick holder bit earlier, there was a gasket stuck to it that was still in perfect nick so it got re-used.

[astrasteve23]

Hi mate van looking mint, i hope to get mine to billing this year never will it be as mint as that tho lol

cheers. its not quite 'mint' yet, doors and bonnet are a different shade of white and the tailgate has a dent in it.

[astrasteve23]

i think its about time for an update.

i done the last 12 car road rally in it on the 8th march (thursday) as the manta isn't on the road yet. we were doing really well and about half way through the last stage my navigator sent me up a white lane (a track that the public can use) basically a 4X4 track!!!! i went on up the track, it was very steep and loose gravel, i was doing quite well, then it got muddy and i still pulled up it at about 15 in 2nd. i got to the top and we realised it was a dead end, neither of us seen the T sign! DOH! so i managed to turn around and head back down, neither of us could believe i made it up there, it was about 1/2 a mile long. it was really bumpy and rutted. anyway we carried on and finnsihed the rally (came last as we lost so much time) and on the way home my oil light kept coming on when i went round corners. i though i was just low as i hadn't checked it for a while. i got home ok, the next morning i checked the oil and it wasn't even reading on the dip stick! i put 2 1/2-3 litres in it and went to work. at lunch time i was driving to bretts and my oil light came on, alarm bells rang! something isn't right! checked my oil at bretts and none on the dip stick again, looked under the van and drip.. drip.. drip.. OH SHIT! i had hit the sump and cracked it! left my car there until after work and pinched some oil off of brett which got me home ok and set to work swapping sumps with the one off my old 1.4. got it done and van back on the road.
pic of cracked & dented sump.
http://xs413.xs.to/xs413/07123/P3090264.JPG (http://xs.to)
http://xs413.xs.to/xs413/07123/P3090266.JPG (http://xs.to)

it had split right by the drain plug.

tonight i re-newed the front discs and pads for new drilled and grooved discs and mintex standard road pads as old pads had about 1mm left and discs were very worn.

new brakes fitted and a couple of coats of red hammerite on the calipers (done in the dark)

http://xs413.xs.to/xs413/07123/P3200312.JPG (http://xs.to)

[GazJevs84]

Looking good fella

At least you got to the sump problem before it got too serious as it could have been alot worse and congrats on the rally mate.

[astrasteve23]

wouldn't of been to bothered if the engine had of died as i would of just fitted the SEH on the weekend. just would of got in the way of other plans.

[astrasteve23]

i might fit the SEH over the easter weekend iv decided.

[astrasteve23]

its going ahead, just about got the old 1400 out but stopped for lunch. im doing it on my own as all my mates are busy but my cousin should be poping over at 3ish to help out.

[mick g]

Hope you finished now cos its going dark:)

[astrasteve23]

just an update. yesterday i got the 1400 out eventually, one of the bolts on the fron gearbox mount wouldn't undo with the massive bar or with the air gun so i had to take the rubber mount off and then the weld on the captive nut it the chassis rail broke so had to get a spanner on that but eventually got it out, replaced the fuel lines with 8mm ones and clips that hold them from a GTE 16v as the standard 6mm & 5mm are to small and were plastic, put the bonnet release pull bracket on, ecu bracket on and cover pannel all from a GTE 16v. i replaced the sump gasket on the SEH and the old gasket was welded on the baffle plate and wouldn't come off with a knife so i have to get a sanding pad in the grinder and sand it all off which was time consuming. this morning i have cleaned the engine bay up, took the steering rack off to change the servo and master cylinder for a GTE non abs one, just got to put rack and GTE front legs on it and drop the engine in and do fuel hose and mount pump & filter and a bit of wireing which brett is going to pop over and do for me.

[astrasteve23]

the engine is in and running but only when drawing fuel out of a can, it wont pull fuel out of the standard tank, i have 10 litres in the tank so its not because there is no fuel in it. the feed from the tank is only 8mm and on injections its 10mm and comes from the sender, i have an injection tank but no sender. i also need heater matrix pipes and the big rad pipe. i will put up some pics some time today.

[astrasteve23]

i found the fueling problem and it was really stupid! there was one jubilie clip not done up tight and it was drawing air in! it runs fine now! i only done a little bit today, just got the front suspension legs and brakes back together, replaced the tempary wireing to the fuel pump, and bled the brakes.

[stt]

i havent got any spare pipes im afraid :(

[astrasteve23]

a few pics i took with my old video camera so they are crappy quality, i will get some better ones when my parents get back from holiday with the digi cam.

http://xs414.xs.to/xs414/07151/v3.jpg (http://xs.to)
http://xs414.xs.to/xs414/07151/v5.jpg (http://xs.to)
http://xs414.xs.to/xs414/07151/v4.jpg (http://xs.to)
http://xs414.xs.to/xs414/07151/v6.jpg (http://xs.to)
http://xs414.xs.to/xs414/07151/v7.jpg (http://xs.to)

[CraigGreen]

Looking good Stev! Brett said it was all happening this weekend.

[astrasteve23]

yeah job done! brett had to come and pick me up and take me to the scrappy and get the plastic water pipe and heater matrix pipes off of a GTE 8v as the cav the engine came out of had abs and i dont have abs so header tank and pipes are different, ecu is temperarily in the engine bay in a carrier bag until tomorrow when i get a hole saw and cut a hole for the loom to go through. today i had to finnish off the wireing, water temp, rev counter & oil pressure, i filled it with water and gearbox oil and started it and got it up to running temp and all was fine and fan cuts in etc and it all works spot on. it drives fine and goes well and doesn't smoke at all. brilliant for 196k!!! the only other thing left to do is remove broken exhaust manifold studs from the head and fit new studs and nuts as it is only held on with 4 out of 8 at the moment and is blowing and sounds like a tractor.

[astrasteve23]

took a few better pics today with the digi camera.

http://xs414.xs.to/xs414/07152/P4100391.JPG (http://xs.to)
http://xs414.xs.to/xs414/07152/P4100392.JPG (http://xs.to)
http://xs414.xs.to/xs414/07152/P4100393.JPG (http://xs.to)

[James C]

That'll shift a bit better now I should have though.

Good job there I reckon! :grinning-smiley-043

[astrasteve23]

oh yeah i am getting the cam cover powder coated white.

[astrasteve23]

yeah it goes ok, not as quick as i expected, the manifold is blowing very bad tho so hopfully when thats done it'll go a lot better. its really torquey, i gave brett a burn up in his cav 1.8 SRi earlier and i only just had the edge, was really close.

[Brett]

i gave brett a burn up in his cav 1.8 SRi earlier and i only just had the edge, was really close.

good old Cav!!

Its much better with this engine in. I think you'll have an XE in there within a year though TBH. Its not as close to the XE in terms of performace as I expected, unless the monifold is really ****ing things up.

[GazJevs84]

Good work fella

[richie00boy]

Steve, is that an Ashley manifold? Does it have the little securing bracket that bolts the end of the manifold to the chassis?

Be careful powder coating the rocker cover, the coating can come off the inside sometimes, and you don't want that all over your cam.

The Astra with that engine should whip the Cav - a good 10 brake more and a lighter car.

[astrasteve23]

the manifold doesn't have the bracket, it is an ashley 4-2-1. i had the snapped studs taken out of the head tonight, fitted all new ones but the new manifold gasket had burnt away where it was blowing so its still blowing quite bad. i will get a new gasket on it and see what it goes like then.

[astrasteve23]

fitted a new manifold gasket this morning and it doesn't go any better, i can hear the engine now tho, its so quiet! bloody good for 196k!

yesterday me and brett went to a local scrappy and there was a white 3 door merit estate so i had the full legnth head lining and all the trim that goes around the rear windows and boot etc, i was going to get the bootlid as mine is dented but the pins wouldnt come out of the hinge so i started cutting it off with my cordless grinder but i took the wrong battery with me that ran out half way throught cutting the first hinge off! i will go and get that next weekend.

[astrasteve23]

i also cut the hole in the bulkhead for the ecu loom and mounted that properly on wednesday night.

[astrasteve23]

headlining is now fitted, i had a slight problem with the induction pipe the other week, it kept sucking in restricting air flow, thats fixed. i have also cut a hole in the air box. i have clocked up 500 miles this week, 100 ish motorway and its been spot on, brilliant on the motorway, as economical if not better on fuel than the 1.4. goes well too, i had a little battle with my mate in his cav sri 16v XE from 0-90 on a private road and i had the edge to 60 then it was pretty even so i was well chuffed with that, didnt smoke at all so it seems like a bloody good engine! hasn't used any water or burnt any oil yet either. really pleased with it.

[astrasteve23]

small update. engine is still going fine, had to put about 1/4 of a litre of oil in it the other day. donr a 300 mile round trip on the weekend without a problem. found out haw the vauxhall alarm works thanks to GRAK, it also has an imobiliser intergrated.
tonight i decided it was about time to put the interior trim bits in that i got from the scrappy a couple of months ago, i waxoiled all in the inner rear arches etc about a month ago, all the trim fitted straight in apart from the side window surrounds at the front as i dont have adjustable height seatbelts and there is no captive nuts to mount them so i will get some welded in then put the 2 bits of trim in. i have to fix the boot carpet to the rear seat. looks much better tho. the whole van needs a bloody good clean before billing.

http://xs216.xs.to/xs216/07244/P6130020.JPG (http://xs.to)
http://xs216.xs.to/xs216/07244/P6130021.JPG (http://xs.to)
http://xs216.xs.to/xs216/07244/P6130022.JPG (http://xs.to)
http://xs216.xs.to/xs216/07244/P6130023.JPG (http://xs.to)
http://xs216.xs.to/xs216/07244/P6130024.JPG (http://xs.to)
http://xs216.xs.to/xs216/07244/P6130025.JPG (http://xs.to)
http://xs216.xs.to/xs216/07244/P6130026.JPG (http://xs.to)
http://xs216.xs.to/xs216/07244/P6130027.JPG (http://xs.to)

[alex]

Good work :)

[DarrenH]

nice job on the interior. is that estate kit ?

[astrasteve23]

yeah its all from a 3 door estste with no sunroof. one came in at the local scrappy so got all the interior trim i wanted and a white bootlid for £25!

[Brett]

feels like ages ago we got all that.. good work:)

[astrasteve23]

it was about 3 months ago i think.

[astrasteve23]

small update.

earlier in the week the screw that holds the rear bumper on in the rear arch came out, one of those 'ill do it on the weekend' jobs, friday night i was driving alony and it suddenly started flapping about and then snapped off, picked it up in one piece, only problem is i cant get anyone to fix it before billing so i am going to have a go at it myself.

http://xs217.xs.to/xs217/07271/P1010064.JPG (http://xs.to)
http://xs217.xs.to/xs217/07271/P1010065.JPG (http://xs.to)
http://xs217.xs.to/xs217/07271/P1010066.JPG (http://xs.to)


also got an irmscher steering wheel fot it and fitted that today


http://xs217.xs.to/xs217/07271/P1010068.JPG (http://xs.to)


also mopped the van with cutting compound and started to clean interior.

[richie00boy]

That break looks pretty bad :(

[Brett]

PMSL at the van this morning with no rear bumper, at least you can show of a rust free backside!! It is a right pain in the arse just before Billing, and the van was looking really good too, but its an easy fix thank thank god.

[astravanmk2]

What clips do you use to fit them on as mine is suffering the same syndrome?

Cheers

[astrasteve23]

you mean how is the rear bumper fixed on the sides? one screw in each wheel arch! its crap, there are lugs in the bumper to take standard fixings but no holes in lower rear quaters i had fitted, i will be fixing it properly tho.

managed to get someone to repair my rear bumper in time for billing hopfully! still got a lot to do tho. still have some of the inside to clean, wax the outside, clean the wheels, spray rear bumper when i get it back, and paint roof rack bars.

[astrasteve23]

my rear bumper has been fibreglassed back together! what a result! tonight i waxed the van, painted the roof rails, and started to filler the rear bumper.

[astrasteve23]

tonight i gave the roof rails another coat of hammerite and done a bit more prep on the bumper to get it looking reasionable then sprayed it, its no way near perfect but it will do for now as i dont have a lot of time, i will do a proper job of it after billing. tomorrow night i have to fit the bumper and clean the back of the van out and load up my stuff ready for billing.

[astrasteve23]

http://xs117.xs.to/xs117/07275/P1010075.JPG (http://xs.to)
http://xs117.xs.to/xs117/07275/P1010078.JPG (http://xs.to)
http://xs117.xs.to/xs117/07275/P1010079.JPG (http://xs.to)
http://xs117.xs.to/xs117/07275/P1010081.JPG (http://xs.to)
http://xs117.xs.to/xs117/07275/P1010080.JPG (http://xs.to)

[Astranomical Lee]

Top job mate good as new?

[astrasteve23]

small update, thrust bearing got stupidly loud and nearly exploded and didnt have time to do the clutch myself so my mechanic mate paul done it for me on thursday because i needed the van on friday. only charged me £20 labour.

[astrasteve23]

about 3 weeks ago i fitted a pair of brand new spax adjustable front shocks that i picked up cheap at billing, also fitted some concentric top mounts, but the bearing in them is too tall and there is not enough thread on the shocks for thr nylon of the nut to lock so have a pair of new standard ones to go on.

also got a set of 14" et42 irmscher wheels for it that have just been professionally re-conditioned and finnished in white.

[astrasteve23]

irmscher wheels are on it, centre caps havent arrived yet, sadly wont be on there for the cheddar meet. fitted new standard top mounts today.

[astrasteve23]

pic of new wheels. should recieve centre caps this week.

http://xs120.xs.to/xs120/07431/21092007061.jpg (http://xs.to)

[astrasteve23]

about time for an update i think, not much done really. lower arm bushes were shot, getting very bad and awfull to drive, so i looked into replacing with the poly ones that people say not to use. the main uk distributer for superflex bushes are only 15 miles from me so i gave them a ring and called in. i have delt with them before and they are helpful, i showed them oddballs thread on why not to use the front bushes, basicly he said that the problem is with the rear ones, when brakeing all the force is being put on the rear bush and pushing it backwards hence the movement at the front mounting. he showed me that their rear bush came with a stainless insert that will stop any movement, no other manufacture of poly bushes use an insert in the rear bush. he said he had never had bad feedback on them at all. i said i wanted to try them and i would take them back off in a few months to check to see if there is any wear to the mounting on the chassis. he gave me good discount and wants me to give him feedback on them. if they are ok he will offer astra-mk2 group buy discount on bushes. so i purchases all the bushes for the front wishbones, fronts, rears and arm links. so last night i took the arms off of the gte in the garage, removed the bushes and ball joints and fitted the superflex bushes which went in quite easy and replaced the ball joints with lockheed delphi ones. tonight i set about swapping them onto the van, took about 2 1/2 hours to do, all fitted ok. went for a drive and its drives much better, so it should as the old n/s rubber bush was completely nackered and had 1/2" of play!!!! time will tell if they are ok and kind to the mountings. i will remove an arm in a few months and do a report on them.


wishbones with front bushes fitted.

http://i193.photobucket.com/albums/z60/astrasteve23/kadett%20van/23042008259.jpg

picture of the wishbone rear bush with stainless insert.

http://i193.photobucket.com/albums/z60/astrasteve23/kadett%20van/gm_vauxhall_astra_mk2_bush.jpg

[DarrenH]

their rear bush might be superior to all others, but it wont stop the pivot bolt bush wearing just because they say so.

you can see from the rear U clamp that its designed to stop lateral movement, not for and aft. the strength in the U clamp is lateral and its open in front and back of the clamp. if any great force was put on the bush, in a for or afte direction, it would just deform out of the back, which is open. the U clamp is even slotted for adjustment for and aft.

i think the sleeve inside the rear bush is a good thing, the standard bush is like this, but to claim it will stop wear on the front bush is preposterous imho

[astrasteve23]

the rear bush is shaped so the clamp slots in so shouldnt push back through, i noticed that the clamp is slotted. how long did yours take before you noticed any wear on the mounting? as i said i will be taking apart and checking in a few months and appropriate feedback will be left to everyone. they come with 3 year warenty, he said if i do get a problem take them back.

[DarrenH]

yeah i see the bush slots into the clamp, but its still a bush, its maluable and will deform when you put 2 tonne of pressure on it.

the wear in the front bush comes from the suspension moving up and down, which tries to undo the pivot bolt, as it succeeds you get play in the front bush and it dominoes from there. it did it in less than a year on mine. the bushes might have 3 year warranty, but our cars do not, its not the bush failing that is at fault.

its definately the best rear bush i've seen aftermarket. best of both worlds, same design as standard but the bush itself is polyurethane. maybe if you have such good relationship and feedback with them, could they not develop the front bush so its a once piece and steel insert like standard ?

[astrasteve23]

yeh i understand what you are saying. at the moment they aren't developing bushes, cant remember the reason, they are made in australia and he is the uk distributer of them so he doesnt do the developing, he has say and does some design and has technical drawings etc. i will speak to him about it tho.

[astrasteve23]

just had 4 new toyo proxy T1-R 195/55.14 fitted to the irmscher wheels, just need to get a paint match and spray the centre caps for them and get them on, also rear bumper will be going into bodyshop soon to get the filler work done properly that i repaired in a rush just before billing last year.

i have also purchased a mk3 astra estste rear beam because the rear hubs can be un bolted and disc brake hubs fitted. on the mk2 estste hubs cant be unbolted. i also got a mk3 cav 2.0 16v SRi rear beam for the disc brake hubs, got both beams for £30 from local scrappy. i allready have new rear discs for a cav, just ordered up new pads and shoes so should have rear discs soon.

[astrasteve23]

fitted 2 new front wheel bearings on saturday, passengers one was humming so thought just as well do both, drivers was still ok but passengers one was fooked. all good now, just have to get tracking done now.

for about a month now my oil pressure has dropped, no light on just lower than it used to be, allways keep oil topped up, it doesn't burn any, smoke, rattle or knock, engine runs spot on just getting 3 bars reading when cold and 1 when hot on tick over, when reved it goes to 3 when hot and full when reved hard, tried a different sender to see if it was that faulty but it isn't. pretty sure its the oil pump as its done 210k, had my mate who is a good mechanic and knows his vauxhalls well to confirm that its oil pump so he is doing that for me next week whilst im on holiday.

[DarrenH]

could be the pump, but big end bearings and mains are a serious consumer of pressure when they are worn.

also worth checking oil pickup o ring.

[Brett]

smokes a bit mate, but thats the tyres normally I guess......

[astrasteve23]

that'll be tyre smoke lol, its never burnt oil.

[astrasteve23]

he didnt manage to get oil pump done when i was away because he was too busy so we done it yesterday morning, crank pulley wouldn't lever off so had to make a puller. new pump fitted, put back together with new gaskets and cambelt and now have full oil pressure all the time, drops i bar on digi dash when hot on tick over but when its reved to about 1300 it is then full.

[astrasteve23]

drove 400 miles today to north wales and back today to collect a straight cut close ratio gearbox with LSD and front coilovers for the GTE, no problems and good oil pressure. and no oil leaks any more, iv sorted them all out now.

[richie00boy]

Good news Steve. Did you get the local pump or the one from Autovaux?

[astrasteve23]

i got the pump from local supplier in the end.

tonight i done some maintenance on the van, fitted new lock set as 2 of them nackered up. also lubricated the electric windows as they would hardly move.
another bootlid i have that is in better condition than mine is going to get sprayed along with the spoiler as that has been flaking since iv had it, also boot handle and petrol cap are getting colour coded so iv been striping down the bootlids tonight too and drilling new one to accept spoiler.

need to give rest of the van a mop with G3 compound and and generally a bloody good clean ready for billing, and re-fit a rear bump strip that got pulled off.

[astrasteve23]

managed to get most of the van mopped today between rain storms. still a bit to do before billing.

[astrasteve23]

bootlid, spoiler, boot handle and petrol cap was sprayed and fitted before billing.

last night i got on with the rear disc brake conversion. i swapped the rear hubs from a mk3 cav SRi 16v rear beam onto a mk3 astra estate beam, also fitted new omp pads to match the front ones, new handbrake shoes on there way and i have some new drilled and grooved discs. also have braided brake hoses on there way. hopfully get the brakes built up and beam fitted one evening next week.

[astrasteve23]

about time for an update i think, not much done really. lower arm bushes were shot, getting very bad and awfull to drive, so i looked into replacing with the poly ones that people say not to use. the main uk distributer for superflex bushes are only 15 miles from me so i gave them a ring and called in. i have delt with them before and they are helpful, i showed them oddballs thread on why not to use the front bushes, basicly he said that the problem is with the rear ones, when brakeing all the force is being put on the rear bush and pushing it backwards hence the movement at the front mounting. he showed me that their rear bush came with a stainless insert that will stop any movement, no other manufacture of poly bushes use an insert in the rear bush. he said he had never had bad feedback on them at all. i said i wanted to try them and i would take them back off in a few months to check to see if there is any wear to the mounting on the chassis. he gave me good discount and wants me to give him feedback on them. if they are ok he will offer astra-mk2 group buy discount on bushes. so i purchases all the bushes for the front wishbones, fronts, rears and arm links. so last night i took the arms off of the gte in the garage, removed the bushes and ball joints and fitted the superflex bushes which went in quite easy and replaced the ball joints with lockheed delphi ones. tonight i set about swapping them onto the van, took about 2 1/2 hours to do, all fitted ok. went for a drive and its drives much better, so it should as the old n/s rubber bush was completely nackered and had 1/2" of play!!!! time will tell if they are ok and kind to the mountings. i will remove an arm in a few months and do a report on them.


wishbones with front bushes fitted.

http://i193.photobucket.com/albums/z60/astrasteve23/kadett%20van/23042008259.jpg

picture of the wishbone rear bush with stainless insert.

http://i193.photobucket.com/albums/z60/astrasteve23/kadett%20van/gm_vauxhall_astra_mk2_bush.jpg


i removed the wishbones just before billing after doind around 3000-4000 miles with them fitted and there is no signs of wear and the bolts were all stupidly tight, i needed 4' of leverage on a breaker bar to undo the nuts! so i am happy with them so far and have no problems to report yet.

[astrasteve23]

there is a bit of an impulse engine swap on its way for the van! i had a good think about dropping in the C25XE i have, i have decided to do it so the van came off of the road on sunday when the tax ran out and i have insured the manta GT/E i have so im drifting that around. lol.
tonight i have started to disconnect everything on the 8v ready to hoist it out. i done a couple of hours on it and got the rad out, coil removed, engine loom and ecu disconnected, throttle and clutch cable disconnected, front bumper and lights removed, airbox out and strut brace off. i just have to remove earth strap, manifold and drive shafts and hoist it out. i did take some pics, will upload them tomorrow.

[Brett]

only just read your text this morning! Cracking on with it. I'll try and help dropping it in if you want, Im busy tonight and tomorrow though!

[Harvey]

Cracking plan Steve, should be nice when it's done.

[astrasteve23]

only just read your text this morning! Cracking on with it. I'll try and help dropping it in if you want, Im busy tonight and tomorrow though!

Im working on it tomorrow night hopfully, i hope to have engine out or ready to lift out.

[astrasteve23]

engine is ready to hoist out whenever, i decided to concentrate on the V6 engine its self and getting the 16v rad mounted.
V6 engine,
iv purchased some vectra X25XE cam covers as the C25XE plastic ones warp and leak oil into plug holes, just waiting on a gasket for that, also got a new dip stick as mine had top snapped off. purchased a mount as well which was missing, also as im not going to be running pas the pas pump is getting modified, a mate of mine that is a mechanic and engineer is going to knock something up using standard mount bracket and a cv joint and a pulley wheel as the alt belt still needs to run around pump to drive water pump. fitted new plugs and inlet gasket.

tonight i had a brainwave about mounting the rad without chopping and lowering the lower crossmember, the rad has to be mounted under the scuttle panell so there is room for the V6 in the bay. i remembered that my irmscher bumper has no impact brace bit and has loads of room behind it, so drilled 2 holes in the bottom of it to locate the 16v rad and the rad fits nicely inside the bumper infront of the crossmember,
http://i193.photobucket.com/albums/z60/astrasteve23/kadett%20van/21122008143.jpg
http://i193.photobucket.com/albums/z60/astrasteve23/kadett%20van/18122008137.jpg
just had to trim a bit off of the upper crossmember stumpy bit on n/s to allow rad to fit. will be using a slimline elec fan as standard one is to big for my idea to work. will add pics when i upload them.
http://i193.photobucket.com/albums/z60/astrasteve23/kadett%20van/21122008142.jpg

[astrasteve23]

just got the disc brake rear beam fitted, new poly bushes fitted and new brake lines on the beam were done before fitting, also brand new drilled and grooved discs fitted and a set of pads and a mk3 astra 2.0 16v estate handbrake cable fitted and the braded brake hoses.

[astrasteve23]

got the 2.0 out this morning but had to get some work done on the manta ready for MOT so didn't drop the V6 in. will try and get it in the engine bay in the week one evening if it isn't too cold.

[astrasteve23]

got new cam covers bolted on with new GM gaskets and o rings. then got engine dropped down into engine bay, need to bold gearbox onto it and then bolt box to mounts, then wait for a mate to weld in a custom drivers side engine mount.

[astrasteve23]

this afternoon i got the F20 bolted up to the V6 and hoisted the engine into place and got all the gearbox mounts bolted up, got most of the loom connected and that was about it. hopfully next weekend get the wireing finnished and get drivers side engine mount done and get flange welded on exhaust and connect downpipes to it.

[astrasteve23]

this morning i done a few more hours on it, got all the water pipes connected, servo vacume connected, front section of exhaust cut ready for flange to be welded on, fitted front braided hoses and had to put a new passengers side copper pipe. i am taking it to a mates place next weekend to get mount done and finnish off wiring.

[astrasteve23]

because of all the ice on the roads we decided not to trailer it this weekend, done a bit on it on sat morning, got the brakes bled, drive shafts in and all back together and gearbox oil in, fuel lines connected and got it back on all 4 wheels. borrowed an engine brace thing to hold engine up to trailer it next saturday to get mount done.
http://i193.photobucket.com/albums/z60/astrasteve23/kadett%20van/14022009187.jpg

[astrasteve23]

got it to my mate pauls on saturday eventually after 1 stub axle snapped clean off the trailer. lol. mount was finnished tonight. i have quite a few pics to put up to update thread which i will try and do tomorrow night. wireing is 99% finnished, exhaust is done so all that is left to do is get an alternator belt and ignition amplifier module, fit rad back on and connect it all up and see if it runs!
new mount uses old rubber mount with rubber burnt out and boxed, so it mounts in standard position.

new mount and idler wheel in place of pas pump.
http://i193.photobucket.com/albums/z60/astrasteve23/kadett%20van/18022009191.jpg
http://i193.photobucket.com/albums/z60/astrasteve23/kadett%20van/18022009192.jpg

[astrasteve23]

pics now added.

got an ignition amplifier module on the way and a shorter alternator belt to fit as pas pump has been replaced with smaller idler wheel.

[Brett]

looking good, our Young one is a legend!

[astrasteve23]

i borrowed an ign amplifier tonight and fired it up, had a small problem, fuel was leaking out of the feed pipe union where it crimps onto the pipe so we sorted that and other than that it all seems ok. only ran it for a while as exhaust is blowing on the centre section and it was quite loud to be running it at 10pm. at least i know my wireing was ok and it runs. got a couple of vids of it running which i will sort out tomorrow.

[astrasteve23]

2 short vids, will get some better ones soon.

1st run short run
http://www.youtube.com/watch?v=6EgP3YtKN88

2nd short run
http://www.youtube.com/watch?v=gJyr6Scnnvs&feature=channel_page

[astrasteve23]

finally got it on the road!

http://www.youtube.com/watch?v=vtAhfQEdvaU&feature=channel

http://www.youtube.com/watch?v=qoiBxjW27ds&feature=channel

[Harvey]

Nice one Steve.

[Brett]

lmao Im used to more speed and noise than that down Strowlands!

[astrasteve23]

i noticed the water was getting blacker and blacker, after 2 weeks of having it on the road it was nearly pure oil! lol. also had the bottom rad hose burst and one of the heater matrix hoses had a pinhole in it and the fuel feed pipe started to leak at the union. took it off the road and put a new genuine GM oil cooler in, and fitted second hand hoses and fuel pipe as bottom rad hose is nls at vaux. flusher water system through and all seems good now. gave it a good thrashing last night and had the front and rear brakes smoking a lot! no fade tho which i was surprised at, i only have standard 16v brakes with drilled and grooved discs and fast road pads all round but they took the abuse ok.

hopfully i will be fitting the brand new -30mm mk3 astra GSi front springs on sat morning as now the heavier V6 is in there it is a lot lower and is way too soft and handles quite badly. will also be getting 2 new tyres fitted and tracking done in the afternoon.

i had a lawn mower in the boot on monday and put it in the wrong way round, had to brake hard, then as i pulled off the mower shot back and the handle went straight through the back window! so i have the old tatty bootlid back on it at the moment.

[astrasteve23]

lmao Im used to more speed and noise than that down Strowlands!

i dont think its possible to go much quicker than that down there!

[astrasteve23]

after fitting the mk3 astra -30mm springs it was sat on the bump stops so i now have fitted a pair of mk3 cav 2.0 16v -30mm springs and they seem ok. other than that the V6 is going very well. i am thinking of selling up now tho and getting a bigger van for work.