Bodywork restoration on Zender Kitted Mk2 [Archive]

Jags C20LET

14-09-2005, 07:32 PM

Yep...it's repairable....2 new full outer sills fitted, £300.(GULP), and thats before a new drivers Door, 2 front wings, and 2 rear outer arch skins, and maybe inner arches too. and then fit a new kit (currently sitting in my loft).....and then a respray....about £2K!!!

These pics are about a year old..If anybody is interested, I'll post some more.
There is also a pic of the air filter / engine bay segrator i made last week...

http://img305.imageshack.us/img305/1527/airbox054uz.th.jpg (http://img305.imageshack.us/my.php?image=airbox054uz.jpg)

http://img332.imageshack.us/img332/3876/stripped038xv.th.jpg (http://img332.imageshack.us/my.php?image=stripped038xv.jpg)

http://img384.imageshack.us/img384/3395/now2hd.th.jpg (http://img384.imageshack.us/my.php?image=now2hd.jpg)

Jags C20LET

21-09-2005, 01:07 PM

Right, the cars booked in for next week for a new pair of full sills....but I'm in a dilemma.
Do I rebuild to current bodywork spec i.e. bodykit and ET20 alloys, or rebuild to standard bodywork (new front/rear wings, and remove the Zender) and buy some nice shiny 17" wheels. This would deffo be less hastle in the long run, insurance, paint cracks on bodykit/panel joins, etc.

What do you guys recon, as I really could do with some input. I'll probably be at Santa Pod on Sunday, and checking out ALL your motors for ideas.

Thanks Guys

_Steven_

21-09-2005, 01:43 PM

The kit looks good, but i personally think with the age the cars are getting, the more original they look, the better.. :)

Astraoid

21-09-2005, 02:28 PM

I like the Zender kit - got one too, but I've aslo experienced hassle as the car has got older - the kit needed cutting to get to repair the rusty sils underneath.

If you do decide to ditch the kit - Please PM me as I'm looking for a spare kit.

Gteman

21-09-2005, 08:29 PM

The kit looks good, but i personally think with the age the cars are getting, the more original they look, the better.. :)

Maybe i'm showing my age but i'm with Steve on this one. They look great modded but if people keep modding them their will be none left original and that would be a sin.

Graham

Jags C20LET

26-09-2005, 05:12 PM

OK...well she went in for the sills today and the nice man at the bodyshop took the arches off while i was there and this is what we found.....needless to say, she needs some (expensive) TLC. Basically 2 full inner arches, 2 new full rear quarters, 2 new full sills, 2 new front wings. I dunno if i can get away with reusing my wheels as they're ET20. That lots gonna cost about a grand, NOT INCLUDING RESPRAY!!!!!!!!!!!

BACK TO STANDARD........Does anybody know where i can get a pair of side-skirts, i binned mine about 7 years ago and I didn't think i'd need 'em again....OH BUGGER...

http://img60.imageshack.us/img60/9507/dsc000369ea.th.jpg (http://img60.imageshack.us/my.php?image=dsc000369ea.jpg)
Yes, that is daylight....

http://img60.imageshack.us/img60/1710/dsc000290nw.th.jpg (http://img60.imageshack.us/my.php?image=dsc000290nw.jpg)

http://img60.imageshack.us/img60/6577/dsc000247tb.th.jpg (http://img60.imageshack.us/my.php?image=dsc000247tb.jpg)

http://img60.imageshack.us/img60/1667/dsc000385wg.th.jpg (http://img60.imageshack.us/my.php?image=dsc000385wg.jpg)

http://img60.imageshack.us/img60/3851/dsc000375yc.th.jpg (http://img60.imageshack.us/my.php?image=dsc000375yc.jpg)

DarrenH

26-09-2005, 05:20 PM

i think most mk2 owners with major projects can relate to those rust pictures. me included. just a shame the skirts are such a water trap, standard stuff too. the kit is quite dated, but its contemporary. its the same age as the car, so i think its cool.

full body resto and put the zender back on, i reckon.

Jags C20LET

26-09-2005, 05:43 PM

Thanks for the input guys, but the decision is made in my head ..well almost....just waiting on accurate pricing....so i may need new wheels....I spy some OZ Record 17" that would house some 308mm brakes nicely.
I also will probably be flogging the kit which is a fibreglass copy, and my spare kit (minus the front bumper spoiler) I will have

both rear bumper corners (x2 sets)
both front bumper corners (x2 sets)
N/S Rear arch (X2)
O/S Rear arch (X2)
N/S Front arch (X2)
O/S Front Arch (X1)
Door Sills (x2 Sets)

I may have to flog the wheels too.......I'll keep any interested parties posted as to what I eventually decide to do.

Dan Gliballs

26-09-2005, 11:47 PM

A grand is a bargain for the whole job sprayed up mate........mine cost almost double that.

I love that arch kit TBH :)

What's the engine spec? That's a great heatshield for the induction kit.............you're giving me ideas ;)

BazW

27-09-2005, 12:23 AM

I like the zender kit, i'd hang on to it as in the future it'll be remembered the same way that the dimma kit is on the 205 gti's

I think theres hardly any of on here that haven't had to do some welding in fact i'm even looking into learning how to weld myself to save a few quid

Jags C20LET

27-09-2005, 11:50 AM

Dan, the bodywork is going to be about £900, maybe £200 more if we use genuine vauxhall rear wings (imported from the land of the big sausage and beer), returning everything back to standard, and then spraying the whole car ontop of that, and probably some new wheels...(OZ Record 17" ET42, 205/40/17....£700), so i'm looking at the fat and ugly end of £2500.....but she'll be bulletproof for years and i'm thinking of getting a sh***er for the winter months (all 11 of 'em).

If anybody is interested, i can post up plans for the heat shield.

Engine spec is:

C20LET from cav @ standard boost
standard cav rad/intercooler/metal fan
piper-X cone filter
cut'n'shut downpipe mated to full magnex exhaust
FSE F.P.R.
F28
Custom strut-brace

205 bhp@5450 rpm / 235 ft/lbs at 3700 rpm
santa pod last year 14.667 @ 96 mph

I was bored so did a VERY rough mock-up of how the beast will look......now and 2 possible afters....waddayarokon?

As she is now
http://img384.imageshack.us/img384/3395/now2hd.th.jpg (http://img384.imageshack.us/my.php?image=now2hd.jpg)

Possible 1
http://img364.imageshack.us/img364/8011/possible019ut.th.jpg (http://img364.imageshack.us/my.php?image=possible019ut.jpg)

Possible 2 - Zender front spoiler and painted rear bumper lip
http://img364.imageshack.us/img364/1613/possible025th.th.jpg (http://img364.imageshack.us/my.php?image=possible025th.jpg)

Dan Gliballs

27-09-2005, 07:40 PM

235 ft/lbs sounds VERY healthy on standard boost :)

Mine knocked out 217bhp before the EDS FMIC, but only 222ft/lbs for some reason...................though it's off to V-Tuning for more 'fiddling' this week ;)

Jags C20LET

27-09-2005, 07:57 PM

http://img190.imageshack.us/img190/8134/dynoplotdetailsremoved0gk.th.jpg (http://img190.imageshack.us/my.php?image=dynoplotdetailsremoved0gk.jpg)

Dan Gliballs

27-09-2005, 08:38 PM

Aye, good smooth curve for an LET :)

Had mine done at Power Engineering too, good bunch of chaps.

Jags C20LET

28-09-2005, 07:03 PM

Todays Visit to the bodyshop.....she's starting to take shape and the wheels definately dont fit....ahhh well.....

http://img171.imageshack.us/img171/9384/inprogress074bz.th.jpg (http://img171.imageshack.us/my.php?image=inprogress074bz.jpg)
http://img171.imageshack.us/img171/1749/inprogress099yu.th.jpg (http://img171.imageshack.us/my.php?image=inprogress099yu.jpg)
http://img171.imageshack.us/img171/7642/inprogress060br.th.jpg (http://img171.imageshack.us/my.php?image=inprogress060br.jpg)

Dan Gliballs

28-09-2005, 08:07 PM

Have they discussed those chassis strengthening plates with you yet mate? (the original skinny ones have probably rotted away now).

They are quite crucial to the rigidity of the car apparently. I got these much beefier babies welded in :)...........................

http://img.photobucket.com/albums/v515/dangly/IMG_0374.jpg

Jags C20LET

28-09-2005, 09:54 PM

Thanks Mate , but I must be blind or something....what exactly am i supposed to be looking at?
Is it the extra thick looking section of sill join you're refering to?

He showed me some strengthening brackets/plates between the inner and outer sills that had rotted and he was going to replace them with chunkier plates, he's also going to mount some chunky jacking points on the sill join lip, as i don't like jacking the car using the pissy jack that vauxhall give you.

Dan Gliballs

29-09-2005, 12:59 AM

He showed me some strengthening brackets/plates between the inner and outer sills that had rotted and he was going to replace them with chunkier plates............

Those are the ones mate ;)

Jags C20LET

29-09-2005, 03:15 PM

Dan Gliballs

29-09-2005, 09:20 PM

Dan, what's the spec on your engine? I've been toying with the idea of a FMIC 'cos I want MORE POWER, but I don't want to cut any strengthening beams and stuff. What do you recon will fit, and how did you do yours? Any info would be a great help.

A mate of a mate brought his 04 reg Impreza WRZ to santa pod on sunday and ran 14.753sec compared to my 14.665, which made me giggle, but i can see him upping the power soon, and i HAVE to beat him again.

Cheers Buddy

I bought this EDS 8.1 litre one off V-Tuning for £250 a few weeks back, it's going in on Monday for a while for them to fit it :) No bodywork needs to be cut, you just lose your front fogs ;) There are much bigger ones on the market, but my car is a sleeper (see 'Sunny Astra Pics' in Show Us Yours section), and I don't want a hugely obvious carved up bumper. This should give 15-20bhp gains and give much more consistant boost even after sitting in hot traffic. I was losing loads of power in the hot months due to the hopeless standard IC and the induction kit sucking all the hot air in aswell.

My engine is virtually standard at the moment, but has a JR induction kit, EVO 2 chips, Turbo Dynamics actuator, Powerflow system,........................and posh Champion plugs LOL!! EVO4 chips on the way though.

http://img.photobucket.com/albums/v515/dangly/IMG_1151.jpg

Jags C20LET

07-10-2005, 01:43 AM

Todays Visit.........

http://img378.imageshack.us/img378/2491/06ospanelsfitted0122td.th.jpg (http://img378.imageshack.us/my.php?image=06ospanelsfitted0122td.jpg)

http://img378.imageshack.us/img378/5691/06ospanelsfitted0423zj.th.jpg (http://img378.imageshack.us/my.php?image=06ospanelsfitted0423zj.jpg)

http://img378.imageshack.us/img378/3931/06ospanelsfitted0624dv.th.jpg (http://img378.imageshack.us/my.php?image=06ospanelsfitted0624dv.jpg)

http://img378.imageshack.us/img378/6193/06ospanelsfitted0722me.th.jpg (http://img378.imageshack.us/my.php?image=06ospanelsfitted0722me.jpg)

http://img378.imageshack.us/img378/3213/06ospanelsfitted0826td.th.jpg (http://img378.imageshack.us/my.php?image=06ospanelsfitted0826td.jpg)

http://img375.imageshack.us/img375/2186/06ospanelsfitted1023fj.th.jpg (http://img375.imageshack.us/my.php?image=06ospanelsfitted1023fj.jpg)

And the inner arch mods to leave loads of room for the wheels....whatever they may be.......
http://img378.imageshack.us/img378/8089/arches7zv.th.jpg (http://img378.imageshack.us/my.php?image=arches7zv.jpg)

_Steven_

07-10-2005, 08:50 AM

Looking good :) .. with the lenghts your going, ask the guy doing it to have a good look at the front door posts, these rot from the inside out. It's not a major task to change them and they only cost about £12 each.

This is when i done mine...

Jags C20LET

07-10-2005, 01:19 PM

Cheers mate. He checked everything over and didn't find anything untoward. Isn't that section you're refering to part of a full sill? If so, it's been changed.

_Steven_

07-10-2005, 01:21 PM

The bit is the panel that covers the door hinges...

richie00boy

07-10-2005, 02:05 PM

Great job. I see you got a full quarter. Where did you get it, how much and what was the fit like? I'm contemplating doing that same area on mine and cant decide whether to get individual panels (rear corner, arch and half sill) or the single one.

Jags C20LET

07-10-2005, 07:22 PM

The rear quarter , and all the other panels are from Hadrian, they all went on without any problem. The rear was about £60 and the front wings were £20ish.
If you really, really want to know, I'll find out exact prices next time i'm at the bodyshop.

richie00boy

07-10-2005, 08:30 PM

Thanks mate, that's close enough on the price. I need front wings as well so it's nice that you mentioned those. I was looking to buy Hadrian panels so it's good to know they fit OK. Did you order them direct from Hadrian?

Jags C20LET

08-10-2005, 01:22 AM

no, the bodyshop did. I know they're Hadrian 'cos theyve still got the lebels on 'em.

I'm now stuck on wheel choice......anybody got any ideas? I really like either chunky softline 5 spokes or chunky hardline 5 spokes , none of this multispoke malarky..these are possible looks, if i can actually get the wheels.

AEZ Icon-5
http://img71.imageshack.us/img71/2121/astraaezicon53ns.th.jpg (http://img71.imageshack.us/my.php?image=astraaezicon53ns.jpg)

MAK Sting
http://img71.imageshack.us/img71/6223/astramaksting0qc.th.jpg (http://img71.imageshack.us/my.php?image=astramaksting0qc.jpg)

Rimstock Pro Race 2 Silver
http://img71.imageshack.us/img71/2635/astrarimstockprorace23rv.th.jpg (http://img71.imageshack.us/my.php?image=astrarimstockprorace23rv.jpg)

OZ Racing Record
http://img364.imageshack.us/img364/1613/possible025th.th.jpg (http://img364.imageshack.us/my.php?image=possible025th.jpg)

_Steven_

08-10-2005, 09:23 AM

The OZ ones look best to me. :)

DarrenH

08-10-2005, 10:53 AM

yeah me too, look a bit like what mike warner used to have... just for illustration...

Jags C20LET

08-10-2005, 02:08 PM

Apparently, the OZ's are available in ET45, so it looks as like they will be the ones, but keep the opinions coming guys!

Dan Gliballs

08-10-2005, 08:14 PM

The bodywork is looking superb matey :)

Jags C20LET

09-10-2005, 04:14 PM

Thanks mate. The bodywork and spraying should all be done in about a week, and i should have the wheels on (with loads of clearance thanks to the inner wheel arch mods). I'm prolly going to pop down and see how it's all going on Monday.
The OZ wheels apparently in a 7 x 17 ET44, which is a strange offset, but only 5mm away from standard, so should be ok.
i'm trying to keep this thread updated as a info sharing exercise, and also for my records.

Jags C20LET

11-10-2005, 09:28 PM

Todays visit....ticking along nicely. The arch mods look as if there will be loads of room for the OZ's. I'l order them tomorrow. Still looking for a rust and dent free drivers door. Full steam ahead.....choo,chooo-chooooooooooooooooooo
http://img447.imageshack.us/img447/6241/06ospanelsfitted140jp.th.jpg (http://img447.imageshack.us/my.php?image=06ospanelsfitted140jp.jpg)
http://img447.imageshack.us/img447/4564/06ospanelsfitted131yq.th.jpg (http://img447.imageshack.us/my.php?image=06ospanelsfitted131yq.jpg)
http://img447.imageshack.us/img447/362/06ospanelsfitted124ng.th.jpg (http://img447.imageshack.us/my.php?image=06ospanelsfitted124ng.jpg)

astrayorkie

11-10-2005, 10:43 PM

looking ripple and rust free now

Jags C20LET

12-10-2005, 12:23 AM

The door looks ok from the pic, but there is a huuuuge crease in it, thanks to somebody trying to put their knee thru it :mad: :mad: So I really need a new door. I have been looking on ebay and "the usual suspects (vpsc, autovaux, etc) but no joy yet.. I dont want to re-skin as they don't last rust free for long.

Jags C20LET

18-10-2005, 08:44 PM

Hahhhh-Haaaaaarrrr! Got a door (with a slight dent in it), no rust and all the electriccy bits, AND a gte bonnet, no rust/dents off e-bay yesterday for the grand total of...................11 QUID!!! I knew that e-bay would eventually be good for something.

All the welding/fitting is done and she's now on the prep stage for the paint. The wheels/tyres turned up today, but unfortunately some t**t sent OZ Super-T's instead of Records!....gotta wait another 2 sodding days AGAIN. Piccs Soon.

Jags C20LET

21-10-2005, 09:07 PM

Todays visit....the wheels arrived and THEY FIT, thank God. I took some more snaps, and it's prolly gonna be about another week.
http://img473.imageshack.us/img473/8952/07prep058lw.jpg
http://img473.imageshack.us/img473/9274/07prep046ie.jpg
http://img473.imageshack.us/img473/4504/07prep033ue.jpg
http://img473.imageshack.us/img473/3931/07prep024gl.jpg
http://img473.imageshack.us/img473/9854/07prep017wj.jpg

Dan Gliballs

21-10-2005, 10:54 PM

Very VERY well blended mate, can't wait to see the end result :)

Just think of all that brand new lovely rust free metal :D

Jags C20LET

22-10-2005, 01:01 AM

Thanks mate, the guy is a master. The £11 drivers door has been totally stripped of all fittings/glass/seals and has been stripped back to bare metal and all dings/dents filled and smoothed, Its also been de-locked.

I must admit, i really am getting excited about getting her back. I've been pootling about in my mums Fiesta 1.1 Duet, which must produce a maximum of about 2bhp and literally slows down to a crawl when confronted with a hill. I also have to call my insurance company and tell the blood sucking leeches that i've actually REMOVED a modification. What do you think my chances of getting some money back are??? (I was joking,...). Thank god the wheels actually fit, and i dont have the prospect of being lumbered with 4 shiny foot-stools.

Jags C20LET

26-10-2005, 10:19 PM

Todays Visit.....Picked up the wheel arch crap-guards after they finally turned up from Germany. all the new metal has been primered and stonechipped, ready for flatting. It looks like about a gallon of paint has been sprayed inside the inner wings, so much that it was actually dripping out out the spot welds in the sills! The welds have been filled beautifully filled and I wired up the flat-oval side repeaters. I really hope she turns out the way i hope. I went abit e-bay mad this week and bought some shiny-things....

http://img409.imageshack.us/img409/1543/07prep132hq.jpg
http://img409.imageshack.us/img409/7809/07prep123us.jpg
http://img409.imageshack.us/img409/6334/07prep118mz.jpg
http://img409.imageshack.us/img409/1981/07prep108rl.jpg
http://img409.imageshack.us/img409/4386/07prep097km.jpg
http://img409.imageshack.us/img409/2779/07prep080iq.jpg
http://img409.imageshack.us/img409/8641/07prep073hh.jpg

Dan Gliballs

26-10-2005, 11:34 PM

Definitely taking shape all the time Jags :)

Jags C20LET

30-10-2005, 11:58 AM

Hi All, I went to VX to order the big black tailgate sticker and was told that they are £68+vat delivery from germany, and that the parts guy ordered one for a guy 3 months ago, and is still waiting for it to come in :eek:

Does anybody know of a good vinyl graphics outfit that could make up the tailgate black sticker and b-pillar stickers for me at a somewhat more reasonable price? I need the b-pillar ones before the glass goes back in :eek:

Thanks Guys....I really am going to be abit stuck otherwise.

_Steven_

30-10-2005, 01:35 PM

Black Magic

30-10-2005, 03:46 PM

i need one of those inner arch making, as i was getting towed other day, i heard it rubbing. Not good, & that was with no weight in it.

Didnt no u cud get the Big Rear quarters. & i also had red GTE doors, u could of had for free. Still trying to get rid now

braders

30-10-2005, 04:34 PM

Ive got a brand new set of stickers to put on mine. Just need to get hold of 1 for the front doors first which i might be in luck with. if anyone knows where to get one for the boot can they pm me and let me know, cheers.

Jags C20LET

31-10-2005, 11:08 AM

Hi guys, right, I have a sample of vinyl in matt with almost the right texture. i got it from the bodyshop, who had it kicking about as leftovers from a kit for a ford. Its made by CD Design. I'll try to find out more info on them.
You can find the GTE logos on ebay

http://cgi.ebay.co.uk/Vauxhall-Astra-GTE-16V-Decal-Sticker-GSI-Nova-Corsa_W0QQitemZ4579187376QQcategoryZ10404QQrdZ1QQc mdZViewItem

The rear quarters are standard size panels, but the inner arch panels have been made from sheet steel, cut, formed and welded to be as close as possible to the outer skin. The outer skin lip was then folded over in order to clamp the 2 together. With the new wheels on (OZ Records ET44 7" wide 205/40/17) there's about 10mm between tyre and arch and there were 2 guys jumping and bouncing the back of the car, with no chance of any rubbage.

http://img378.imageshack.us/img378/8089/arches7zv.jpg

Black Magic, thanks for the offer of the doors, typical isn't it. I once bought a new AFM for my XE (£220 IIRC :eek: ) only to be offered one for £20 the next week :(

Thanks for the interest in my baby, the bodyshop is abit snowed atm, but for the price i'm paying for all this work I can't really complain about the length of time that I'm without my car. I'll Keep y'all posted about the graphics.

Jags C20LET

04-11-2005, 07:00 PM

Red stuff covering my car!!!!!!

http://img459.imageshack.us/img459/7464/08painting016hj.th.jpg (http://img459.imageshack.us/my.php?image=08painting016hj.jpg)

http://img459.imageshack.us/img459/8104/08painting027no.th.jpg (http://img459.imageshack.us/my.php?image=08painting027no.jpg)

http://img459.imageshack.us/img459/4633/08painting038gl.th.jpg (http://img459.imageshack.us/my.php?image=08painting038gl.jpg)

http://img459.imageshack.us/img459/6455/08painting045pr.th.jpg (http://img459.imageshack.us/my.php?image=08painting045pr.jpg)

_Steven_

05-11-2005, 10:48 AM

looks good!... gonna be plenty of red ones about..

Not long since got mine back
http://www.astra-mk2.com/steveheley/paint1.JPG

braders

05-11-2005, 01:50 PM

Heres mine from a couple of months ago. :)

http://img489.imageshack.us/img489/3420/im0007891nc.jpg
http://img188.imageshack.us/img188/4521/im0008170hr.jpg

2nd pic is from when it was nearly complete minus the trims and that.
Cant stop polishing it now though :D
Its good to see these old astras put back to how they should be and not left to rot.

Jags C20LET

05-11-2005, 07:44 PM

Wow, lots of shiny astras everywhere. Top work y'all! I should have her back at the end of next week. The sprayer was well narked when he came back to find a few fish-eye marks on the paint, maybe from air or silicone contamination, but he says it'll all flat-out lovely, and there's about 6 coats of paint on the new metal. i'm really pleased with the results so far. The new door has been flatted and de-locked and de-dinged to perfection and will be sprayed on monday.

As far as the tailgate/b-pillar stickers is concerned......... i found a company that can supply me the vinyl in a very close match, apart from the grain texture, but like i said, very close.....the only snag is that the roll it comes on is 235mm wide, and the tailgate sticker is 240mm. If anybody is interested, i can probably get as much as is needed for about £30, enuff for the tailgate and b-pillars. The dude from the shop is trying to get the right size for me....i'll keep interested parties posted, via here.

Jags C20LET

09-11-2005, 07:29 PM

The paintwork is going swimmingly.....the photos below were taken with a phone and without a flash. I couldn't believe how shiny she is. All should be done and dusted by Wednesday next week. I'm going to give the Graphics shop a prod as the b-pillar black sticky stuff needs to be back on before the rear glass frames are glued back in.

http://img324.imageshack.us/img324/8061/08painting071sw.jpg
http://img324.imageshack.us/img324/3610/08painting066od.jpg
http://img324.imageshack.us/img324/7229/08painting055hg.jpg

Jags C20LET

15-11-2005, 11:44 PM

Almost there..........i picked up the vinyl for the black sticky stuff, i'll make sure its hunky-doory tomorrow (still got 18 days annual leave to take by dec 22! Poxy "having-to-work-over-Christmas" ). The wheels are going to go on at the last minute, to avoid any chance of any crap getting on them. I took some snaps today...wadda ya recon?

http://img333.imageshack.us/img333/9735/08painting120de.jpg
http://img333.imageshack.us/img333/4710/08painting110ii.jpg
http://img333.imageshack.us/img333/5224/08painting108dc.jpg
http://img333.imageshack.us/img333/9057/08painting093rd.jpg
http://img333.imageshack.us/img333/5333/08painting087qg.jpg

richie00boy

16-11-2005, 10:01 AM

Looks great Jags. Where are you based?

GazJevs84

16-11-2005, 03:47 PM

looking good mate but will look a whole lot better with the black stuff back on

Jags C20LET

16-11-2005, 04:24 PM

Thanks for the feedback guys. I'm in the south-east. London/reading area..........The most un-happy town in the uk.................

Could somebody measure their tailgate big black sticker please? I think i made a bo-bo when i measured it and ordered the wrong size material for the new one.....DOH! :eek:

Jags C20LET

26-11-2005, 11:25 PM

Just a little buffing and a small rust hole in the drivers footwell to do and i can have her back.............NEARLY THERE!!!!!

The sideskirts are bonded on with windscreen glue, so no holes to rust....just hope i never have to take 'em off!

http://img386.imageshack.us/img386/2639/08painting195wu.jpg
http://img386.imageshack.us/img386/9786/08painting160wi.jpg
http://img386.imageshack.us/img386/9703/08painting142mr.jpg

GazJevs84

27-11-2005, 12:40 AM

looking good mate when you putting the black stuff on

Harvey

27-11-2005, 10:30 AM

Very nice, just wish the body shop would pull their finger out and get mine done.

Jags C20LET

27-11-2005, 12:28 PM

The rear bump strips will go back on when i've cleaned 'em up to a satisfactory level. I don't know if i want the tailgate sticky on or not, I think it looks better without it.?!

Harvey, how long have you been waiting for yours then?

What do you guys recon to the wheels, did i make the right choice?

Dan Gliballs

27-11-2005, 01:21 PM

Looking superb matey!! :)

Not sure whether to leave my black sticky strip off the tailgate when I replace it, yours DOES look good without :cool:

Daza

27-11-2005, 02:56 PM

Looking really nice mate. Not sure about the sticker on your rear window though!

braders

27-11-2005, 04:07 PM

are they new side rear window rubbers, if so where do you get them from? looking good mate.

Jags C20LET

27-11-2005, 04:19 PM

are they new side rear window rubbers, if so where do you get them from? looking good mate.
Thanks, y'all.

No, mate, they're my old ones. Just been cleaned up a bit. Why? Can't you get them from Vx anymore?

Jags C20LET

29-11-2005, 09:02 PM

Ahh.haaaaaaaaaaaaaaaaaaaaaaaa, she's back!!!! :D :D :D :D :D

I've got tomorrow off work to clean out the inside and refit the c/locking actuator, and adjust the drivers door postition. Pics tomorrow.

GazJevs84

29-11-2005, 11:41 PM

glad to hear bet you r well chuffed make sure you post pics tomoz lol

Jags C20LET

03-12-2005, 09:17 PM

The rain has made it hell to take any decent pics, and i picked up the kebab car today (donner....... getddit,geddit?) so i'm going to start gutting the interior soon. Anyhoo, pics soon.

braders

04-02-2006, 02:39 PM

any pics now its finished?

ashtray

04-02-2006, 03:31 PM

looking well sweet m8 another gte saved from extinction :applause: :bananajump:

Jags C20LET

07-02-2006, 01:11 PM

Cheers mate. i haven't added to this thread in a while, but some pics soon. I just changed the pas rack, which isn't fun if one of the servo mount bolts is rounded and you cant get the allen key to get a hold....out comes the power drill! i've "just" got to get the wipers/scuttle back in and then get the dash out of the kebab, and plonk it into mine, which has had the dash stripped out already. I just finished tydying the looms with cable wrap, and labelling everything.

Once thats all done, the carpets can go in and then the new seats. THEN and only then is she finished.

Jags C20LET

22-02-2006, 05:55 PM

Right. The dash went in today, it was a bit of a headache, but it's in. All the loom has been spirowrapped and cable tied to the dash tie points. Its now VERY tidy inside there.
Rubber "u" section seal has been fitted to the winscreen side of the dash, to reduce any chance of squeekage. The scuttle panel is back in. The washer jets have new 5mm clear poly-tube tubes and the washer bottle has been give a damn fine clean. The windscreen wipers are now both drivers side ones so i have 2 wind deflectors. Just waiting for my red LED bulbs to turn up, and i can put the switches and heater controls back in .................

Jags C20LET

01-03-2006, 07:13 PM

Just got my new cone filter. It fits directly onto the AFM. It's part of K+N's universal range and is part number RD-3250, £52 from Power Engineering in Uxbridge. It's a nice size, fits the available space nicely, and looks lurrrrrrvely.

Old against new
http://img103.imageshack.us/img103/5839/01032006062small7cj.jpg

Fitted.
http://img103.imageshack.us/img103/7091/01032006063small7om.jpg

whitegte

04-03-2006, 03:35 PM

do you still have zender kit mate or was it distroyed when removed

Jags C20LET

04-03-2006, 08:59 PM

Nope, it survived. Basically I have most of the bits of 2 kits.
i have a complete kit (minus front lip and drivers arch) , FIBREGLASS, NEW AND UNPAINTED. and all the bits from the one i took off, once again minus the front bumper lip spoiler. The front extensions are still attached to the wings. Why?

Jags C20LET

04-03-2006, 09:06 PM

The renovation is drawing to an end, or so i thought. TodaY i got the rear seats and carpet in, and spotted a bump in the soundproofing in the passenger footwell. A few prods later and this is what i found.

http://img139.imageshack.us/img139/9976/04032006066small3di.jpg.

It looks like exactly the same problem as i had on the drivers side, oh well, back to the bodyshop for some welding and plating.

Jags C20LET

11-03-2006, 03:29 PM

Well, it's been plated, I can start putting the carpets back in now.... Plate on the inside, hammered flat on the outside, and 4 x 8mm bolts to squeeze the lot together, and underseal on both sides.

http://img238.imageshack.us/img238/1442/09rustyfootwell02small4os.jpg
http://img122.imageshack.us/img122/4316/09rustyfootwell03small9br.jpg
http://img122.imageshack.us/img122/3252/09rustyfootwell04small2bb.jpg
http://img122.imageshack.us/img122/193/09rustyfootwell05small4gf.jpg

Jags C20LET

19-03-2006, 04:06 PM

Yesterday..........

http://img112.imageshack.us/img112/1349/18032006098small3nj.jpg

http://img466.imageshack.us/img466/5444/18032006099small4ka.jpg

http://img466.imageshack.us/img466/7214/18032006100small0cq.jpg

whitegte

19-03-2006, 06:19 PM

will you be selling zender kit if so how much mate, car is looking sweeeeet will start work on mine in a few weeks hope it ends up half as good as that

Gteman

19-03-2006, 07:21 PM

Where did you get and how much is the soundproofing ??

Looks great by the way ;)

Graham

19-03-2006, 07:23 PM

Looking fantastic, remember getting mine back from the bodyshop 3 years ago and it looked so clean and shiny it put a nice warm feeling inside you. (or is that just me)

Jags C20LET

20-03-2006, 01:38 PM

Right lads,

the sound deadening is from the bodyshop. it comes in a pack of 4 bitumen sheets 22" square. I dont know how much it costs, the owner let me have it. I'll find out if you want, i still have the box and will post up details.

I still need to pile up all the bits of the 2 kits i have, and yes, i do want to shift them. I'll let you know what i've got and maybe you can make me an offer?

Thanks for the interest. once the carpets back in,. i can finish the dashboard, and then she's done. I still need to install my stereo, and have made up a modified ISO lead to tap off what i need to power my toys (12v, 12v switched and illumination for gps, boost gauge, and AFR) instead of cutting into the loom all over the place../....But, with my insurance woes atm, she may be sat on axle stands in my garage until September:hissyfit:

Jags C20LET

29-03-2006, 01:58 PM

Hi all,
I finally took a couple of pics today.

http://img72.imageshack.us/img72/1653/28032006112large8rn.jpg

http://img72.imageshack.us/img72/8279/28032006113large5eu.jpg

The interior is not far from being finished now. I've also labelled up all the switches and connectors. All the bulbs and LCD illumiation had been changed to red lighting (looks very cool at night)

http://img72.imageshack.us/img72/9132/28032006114large5nt.jpg

http://img72.imageshack.us/img72/8383/28032006115large7db.jpg

Hopefully it wont be long now. I can only use her for another 2 weeks before i cant afford to insure her, so i want to have her finished by then.

Addz

29-03-2006, 03:35 PM

Looks great mate!

Personally I would have colour coded the sideskirt as well but thats just me lol

therugtugger

29-03-2006, 06:54 PM

my gte is 18 years old and is doing very well in condition but has lots cash flashed at it to keep it ship shop con:Banane47:

richie00boy

29-03-2006, 07:01 PM

Looks good Jags, like the detail of the proper labels on the wires!

Defiance

29-03-2006, 10:35 PM

Hiya'
Looking fabulous Jags

If you mind me asking which fillers/stoppers have you used ?? as the result looks amazing

Cheers

Ciao

Def

Gteman

29-03-2006, 11:06 PM

It would be great if you could post details of who make the sound proofing.
Should be needing it soon i hope. :)

Jags C20LET

30-03-2006, 02:03 PM

Hi Def, sorry i have no idea which fillers and materials the bodyshop used, next time i'm down there, i'll ask for ya.

Gteman, sorry mate, i was going to post the details yesterday, but my aunt had a stroke and passed away yesterday:( so not had much time at home. will do asap though.

Defiance

01-04-2006, 07:15 PM

Hiya,
Cheers Jags

Sorry to hear about your aunt passing away jags :(

Take Care

Def

Jags C20LET

02-04-2006, 02:48 PM

Cheers mate, i appreciate it alot.

curly

13-04-2006, 07:43 PM

Hi!
Just wondering wether you still have the zender bodykit for sale as i am looking for one for my mk 2 gte ?

Jags C20LET

20-04-2006, 08:27 PM

The progress so far.......the only thing holding me up now is trying to graft in the trip computer....i think its going to go where the centre vents are...relocate my boost gauge to where the unused buttons are on the instrument cluster surround LHS (opposite the fog switches).

I'll prolly fit my chrome rocker cover this weekend, i tripped and nearly broke my toe on it last night.

http://img232.imageshack.us/img232/282/05reassembly01carpetsrefittedl.jpg

http://img232.imageshack.us/img232/8670/05reassembly02centreconsoleref.jpg

http://img467.imageshack.us/img467/158/05reassembly03heaterandtaperef.jpg

http://img232.imageshack.us/img232/4104/05reassembly04heaterandtaperef.jpg

Jags C20LET

30-04-2006, 06:54 PM

mmmmmmmmmmm......shiney.

http://img269.imageshack.us/img269/4302/chromerockercover05fitted01lar.jpg

Defiance

30-04-2006, 07:08 PM

Hiya,
Lubly Jubly m8

Looks beautiful

Ciao

Def

mikey g

14-05-2006, 08:04 PM

looks nice that, what are those things for under the seats? i got some of them when i changed my interior i no they go to the heater

richie00boy

14-05-2006, 08:47 PM

The keep the rear passengers feet warm.

mikey g

14-05-2006, 09:00 PM

that would make sence!!

im in the middle of fitting a zender kit now just need the bumper extentions then im away

Jags C20LET

11-07-2006, 11:39 PM

Right, the latest mod.....new battery terminals (earths and alt / starter cables)...not really needed, but i have access to a proper crimper, so why not?!

http://img399.imageshack.us/img399/9268/batterycablesreplacement01larg.jpg

http://img392.imageshack.us/img392/2347/batterycablesreplacement02larg.jpg

http://img399.imageshack.us/img399/1033/batterycablesreplacement03larg.jpg

http://img74.imageshack.us/img74/1575/batterycablesreplacement04larg.jpg

http://img392.imageshack.us/img392/6852/batterycablesreplacement05larg.jpg

http://img399.imageshack.us/img399/7947/batterycablesreplacement06larg.jpg

http://img399.imageshack.us/img399/1811/batterycablesreplacement07larg.jpg

Tony25

12-07-2006, 09:20 AM

Liking the new cables, do you notice any difference, when starting etc??

Jags C20LET

12-07-2006, 10:34 AM

no! she's always started on the button (pretty much). I only did it 'cos i was going to uprate the alternator to a 90a or a 120a, and the alternator cable is only a piddly 10 sqmm. The positives are now 25 sqmm (good for 136a) and the earths are 16 sqmm. The whole lot including the battery clamps was about £35.

Jacko

14-07-2006, 03:44 PM

I got a black sticker for the rear and the only one still available is the early type with the GTE cut into it. I must admit i did wait a long time for a complete sticker set.

Me and Meady have hunted high and low to try and match up the vinyl, but it turns
out it was made specially for Vauxhall by 3M.

BUT.. there some must something similar somewhere.. ?

Hi guys, i'll start by saying thats a lovely looking mk2 you have yourself there mate, :thumbsup:whats the total on all that work if you don't mind me asking? And where are you based? I could do with some TLC from a garage, and don't trust anyone i've come across yet

us lot on the mk1oc.com are getting a supply of the orignal vinyl from 3M This is the url for it (http://solutions.3m.com/wps/portal/!ut/p/kcxml/04_Sj9SPykssy0xPLMnMz0vM0Q9KzYt3d9KP0I8yizeIN_Jx0S _IcFQEAN-SQdQ!?PC_7_0_B1S_root=K3BHNB8005gv&PC_7_0_B1S_output=html&PC_7_0_B1S_gvel=S2N815KHQ0gl&PC_7_0_B1S_vroot=206X7CMQMPge&PC_7_0_B1S_node=FXMG9J3GXZbe&PC_7_0_B1S_theme=exterior_portal&PC_7_0_B1S_command=AbcPageHandler) if you fancy having a buchers. If you want some ona roll then let me know and when we have a decent enough amount of the stuff i'll let you know.

Sipo

14-07-2006, 07:35 PM

Jacko I would imagine there would be a LOT of people wanting to sign up for this. I know there was some replica stuff being sold by Harvey at Retro, but I didnt actually get a chance to see how similar it was.

Jags matey, Ive only just noticed that the exhaust in the 1st set of pictures comes out on the opposite side. Any ideas why that was?

Jags C20LET

14-07-2006, 09:01 PM

jacko.........thanks mate, i'm really pleased with the results myself! The rebuild, respray, new wheels, totalled £2500...if that sounds verrrry cheap, that's because it was done on a "in between jobs" basis and took about 2 months. Luckily i had a car to use during the work. the donor car for the interior (and spares) was £300, but in total, including all the little bits, i'd say probably say about a tad over 3grand.

Hi Sipo, Ahhh, "that photo"........

http://img384.imageshack.us/img384/3395/now2hd.th.jpg (http://img384.imageshack.us/my.php?image=now2hd.jpg)

sorry, i cheated as i needed the pic with the tail on the left, i reversed the photo (if you look really close, you can see the gte badge is reversed)

Sipo

15-07-2006, 11:35 AM

Aha, oh yes I see it now ;)

red top lee

24-07-2006, 07:37 PM

very very nice

Jags C20LET

24-07-2006, 11:01 PM

Why.... thank you very much, Sir :thumbsup:

Jags C20LET

30-07-2006, 09:14 PM

For those parties interested in the purchase of my zender kit bits, i finally gathered up all the bits today, so this is what i have...

DRIVERS SIDE

Front bumper Extension--------------2 old painted
Front Arch Extension-----------------2 old painted
Sill----------------------------------1 old painted / 1 new virgin
Rear Arch Extension-----------------1 old painted / 1 new virgin
Rear Bumper Extension---------------1 old painted / 1 new virgin

PASSENGER SIDE

Front bumper Extension--------------2 old painted BROKEN DURING REMOVAL
Front Arch Extension-----------------1 old painted / 1 new virgin
Sill----------------------------------1 old painted / 1 new virgin
Rear Arch Extension-----------------1 old painted / 1 new virgin
Rear Bumper Extension---------------1 old painted / 1 new virgin

Basically, 7 new bits, and 13 old ones. The old pieces are still covered in crap, one is cracked, some have bits of metalwork and bonder still attached, but the new bits are absolutely perfect. basically there 2 kits there with a front passenger side bumper extension with a bit broken off and missing, and no front lip spoiler.

I WILL POST PICTURES IF ANYONE IS INTERESTED.......bearing in mind these kits were £300 a set, and there's two here........i'm open to sensible offers, if none recieved, it's going back into my loft!

Cheers y'all

....edit - pics added

http://img346.imageshack.us/img346/6415/30072006526largeyc3.jpg

http://img346.imageshack.us/img346/8807/30072006527largeef3.jpg

http://img346.imageshack.us/img346/4688/30072006528largewu4.jpg

http://img321.imageshack.us/img321/3927/30072006529largeub5.jpg

http://img346.imageshack.us/img346/1761/30072006530largefc9.jpg

http://img321.imageshack.us/img321/765/30072006531largezc4.jpg

http://img474.imageshack.us/img474/4195/30072006533largetl2.jpg

curly

05-09-2006, 04:51 PM

I'm interested how much for used setwith and without bumper extensions

Jags C20LET

08-09-2006, 12:43 AM

if i'm gonna sell, i'd prefer to sell the lot in one go, but.......make me an offer, i can only say no!

Addz

08-09-2006, 10:34 AM

Hi mate, great thread! Really interesting reading.

Just wondering where you got the cabling from to uprate the starter wiring? Most of the cabling ive been looking at says its not suitable for wiring up starter motor and alternator. Where did you get it from, and what gauge is it?

Am i right thinking you have relay'd your headlights? Info on this would also be great! :D

Jags C20LET

08-09-2006, 07:41 PM

Cheers Buddy!

The standard brown looks like 10mm and reds look like 16mm so i uprated 'em , cos i could!

The cable is from CSE Industrial Electrical Distributors, Bourne End 01628 529448.
http://www.cse-distributors.co.uk/cable/tri-rated-cable.htm

It's pukka industrial 3 phase motor cable. Tri-rated flexible. The brown is 100amp 16mmsq (6AWG) £3.09/metre and the red is 125amp 25mmsq (4AWG) £4.76/metre.

You'll need to get 'em Propper Hexagonal crimped too.

errr...no, i haven't relay'd my lights, but may get around to it at some point. That relay in the pics belongs to the rad fan.

http://img179.imageshack.us/img179/3224/radfanbypassrelaycircuitlarge4.jpg (http://imageshack.us)

Addz

08-09-2006, 08:49 PM

Hexagonal crimp? How much are they?

I have a normal type crimp is that any good?

And as for the fan relay, is that so it doesnt make the massive battery drop when it cuts in? Mine nearly makes the engine stall when it happens and its just idling!

Jags C20LET

08-09-2006, 09:51 PM

naaah mate, the idea behind the relay is to take the load off the cable that runs thru the car and to the fusebox, in an attempt to remove the possibility of the "melted rad fan fuse" threat.

the lugs are only about 15p each, but you need to crimp the lugs on the ends of the cable.

when you say you have a normal type crimper, do you mean one that does red/blue/yellow insulated crimps? if so, then its waaaaaaay too small to crimp a 16 or 25mm cable lug.

there are 2 types of crimper. first is the "dimple" type, that basically squishes the crimp from at single point and the rest deforms into a "V" shape .... cheap/not very reliable. a hex crimper crimps the lug onto the cable and turns the round bit that the cable goes into into a hexagon, this ensures maximum clamping force on the cable, this type of crimper is usually in the 4-500 pound range. see this link for the type of thing i mean http://www.waynespicer.com.au/crimpers.html

we've tested hex crimped cables to 50000 newtons before pulling out.

if you ware local, i could take the cables to work with me and do them there.

1800turbogte

30-11-2011, 09:25 PM

Hi Jags very interesting thanks for putting the link up on my thread it confirms that I should go standard.:)

Chris

mrdezzer

01-12-2011, 07:30 PM

Another good thread wish you could still get hold of the hadrians full rear quarters :(

Jags C20LET

01-12-2011, 11:33 PM

Another good thread wish you could still get hold of the hadrians full rear quarters :(

Thanks for the comments chaps. Yes, I wish that I'd bought a couple (or 20) panels at the time!

1800turbogte, you are very welcome!

easytrans

02-12-2011, 12:05 AM

there are 2 types of crimper. first is the "dimple" type, that basically squishes the crimp from at single point and the rest deforms into a "V" shape .... cheap/not very reliable. a hex crimper crimps the lug onto the cable and turns the round bit that the cable goes into into a hexagon, this ensures maximum clamping force on the cable, this type of crimper is usually in the 4-500 pound range. see this link for the type of thing i mean http://www.waynespicer.com.au/crimpers.html

As a last resort you can make a crimping component to fit into a vice (bench vice if the cables are not fixed to the car) by either using the "clamping" components of a cheap pipe flare tool that you can buy similar to this ....

http://www.toolbuddy.co.uk/ekmps/shops/toolbuddy/images/toolzone-double-brake-pipe-flaring-tool-kit-296-p.jpg

Or even more simplistic by fabricating a clamp from either a split steel nut (cut in to two halves) obviously choosing one of a correct size centre to crimp your lug, or fabricate from a small steel block drilled to just smaller than your lug and then sawn in halves.

Ok it requires some time and effort but a cheap tool to make ;)

Laurie.

Jags C20LET

03-12-2011, 07:20 PM

As a last resort you can make a crimping component to fit into a vice (bench vice if the cables are not fixed to the car) by either using the "clamping" components of a cheap pipe flare tool that you can buy similar to this ....

http://www.toolbuddy.co.uk/ekmps/shops/toolbuddy/images/toolzone-double-brake-pipe-flaring-tool-kit-296-p.jpg

Or even more simplistic by fabricating a clamp from either a split steel nut (cut in to two halves) obviously choosing one of a correct size centre to crimp your lug, or fabricate from a small steel block drilled to just smaller than your lug and then sawn in halves.

Ok it requires some time and effort but a cheap tool to make ;)

Laurie.

You are a braver man than me, my friend!