GTE valver fast road/track car project

[Harvey]

Already got a pickup pipe sorted with the Z20LET pump I had off Anthony. Steve made the pipe originally as it was from a late Frontera 2.2 before it got chopped about by him :thumbsup:

[Harvey]

Not much progress with my engine rebuild as I’ve lost my enthusiasm but hoping to get some for Christmas!!!

Been buying yet again and have finally got myself a shift light. Spent a while researching it and finally decided on a Shift-I, more details about them here (www.shift-i.co.uk). They are made in Australia and I purchased mine from Squaredeals (http://www.triumph-online.co.uk/electrical--instrumentation-47-c.asp) a UK Triumph motorcycle specialist as the Shift-I are aimed more towards the 2-wheeled market but work just as good on cars. I’ll do a proper review once I get the GTE up and running next year.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC041210Medium.jpg

How it’ll look when fitted.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC041214Medium.jpg

As my engine is in bits I decided I should sort something with the sump to stop oil surge. Oil surge is when the oil gets thrown front to back under acceleration and side to side when cornering in the sump and the oil pickup becomes exposed and sucks up air. This can cause premature wear in the crank bearings and engine failure. There are a few baffled sump designs out there but I wanted something proven to work. After looking round the various Vauxhall forums I spoke with Matt (MPH on here) as he runs an ex Jim Russell mk2 race car and has also completed a mk3 build running a very similar spec engine to myself. Matt has designed and built a gated and baffled sump himself and has been running it on his mk2 for a number of years. It is actually fitted to the underside of the windage tray and not in the sump like most rwd designs. Matt’s design is also gated which allows oil to flow freely towards the oil pickup but also holds it there due to the gates so under hard cornering there is less change of the oil getting away from the pickup and thus causing oil surge. Initially Matt had never seen the 8V bonded windage tray so wasn’t sure if the TIG welding would damage the rubber. Any after a few weeks I got a txt to say all was done and the bonded rubber was fine. I’m really pleased I didn’t have to use the original 16V windage tray I also supplied as they can be a pain to properly seal as you will all know. A huge thanks to Matt for all your help with this.

Original 16V windage tray which can use either the double cork type gaskets or the rubber 8V u-shape design.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PB171206Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PB171209Medium.jpg

The 8V bonded windage tray now baffled and gated to Matt’s own design. I'll get some more pics when it's fitted and before the sump goes on.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC171215Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC171216Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC171217Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC171218Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC171219Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC171220Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC171221Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC171222Medium.jpg

[Keif]

Good on you, it's about time tho.

I know what you mean about enthusiasm, let hope Santa brings you some.

[mick g]

Nice bit of welding there mate:thumbsup:

[Nova Ian]

Nice work Harvey, glad to see your still getting some work done on the old girl!

That baffled sump looks good, will have to consider one for the nova I think.

Not had chance to do anything on mine since moving house, but atleast now its in the garage outside so will be able to crack on with it.

Have a nice christmas and new year mate and im sure we'll catch up next year at some point.

[Harvey]

As you can guess I’ve still not got my engine rebuilt, I do have everything ready for the build but I’ve just not been bothered to do it yet.

Another piece of the jigsaw arrived on my doorstep, literally, at 06:30 this morning so a HUGE thanks to Keif and his night shift.

May I present a plugged sump hole and a drainable F20 diff cover plate.

Sump
The hole
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/DSC01955.jpg

Blanking plate fettled to size.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/DSC01973.jpg

Face cleaned for welding.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/DSC01974.jpg

Plate prepared for welding.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/DSC01978.jpg

Ready to be stuck together.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/DSC01979.jpg

Sticking in progress
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/DSC01980.jpg

Stuck
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/DSC01981.jpg

Diff Cover
Position marked out
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/DSC01977.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/DSC01976.jpg

Hole drilled and being opened up to size.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/DSC01982.jpg

Cleaned and prepared for welding
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/DSC01984.jpg

Boss machined with pilot hole.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/DSC01983.jpg

Welded in place.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/DSC01985.jpg

Drilled and tapped (by hand! Keif's to be exact)
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/DSC01986.jpg

Plug in place and checked for a tight seal
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/DSC01987.jpg

[mick g]

Quality work as always, are you intending to drain the gearbox periodically?

[Belmont turbo]

looking good will it be built for the summer? i need a keif! lol

[himselfunknown]

You're not leaving anything to chance are you Harvey?! But then again, with the time, money and effort you've put into this awesome car, I guess it pays to!!

[Harvey]

Quality work as always, are you intending to drain the gearbox periodically?

I just got peed off with the F20 as there is no drain plug as standard like on the F28 and later boxes. I've got loads of the Millers transmission fluid and as my box cost quite a bit to get it sorted changing the fluid once a year is a no brainer to me and the drain plug will make life so much easier.

I'm hoping to make a start on the engine rebuild this weekend, honest guv.

[Keif]

looking good will it be built for the summer? i need a keif! lol

It better be, and :rofl:


I just got peed off with the F20 as there is no drain plug as standard like on the F28 and later boxes. I've got loads of the Millers transmission fluid and as my box cost quite a bit to get it sorted changing the fluid once a year is a no brainer to me and the drain plug will make life so much easier.

Will be SO much easier with the drain plug in, i recently changed the gearbox oil in my MK4 Astra and thought it was a stupid set up with out.


I'm hoping to make a start on the engine rebuild this weekend, honest guv.

:shocked:

:applause:

[DarrenH]

awesome tigging there

[DarrenH]

forgot to say. that sump and oil pump. you essentially have the best wet sump setup available.

with the new steel rods already done, this engine could take 8500rpm, and beyond 230bhp with cam swap and remap :D

[Harvey]

Thanks for the info Darren. To be perfectly honest I'm more than happy with what I have as the power curve is awesome as it's all the way from nothing. If I stick cams in and had a remap I would loose the low end but gain more at the top. I just want to get the engine and car bullet proof as when it was on the road I had way too many niggly issues that were very annoying. Hopefully this time round it'll be all sorted.

[vaughanmc]

Very very nice car mate! :)

[Harvey]

After last minute overtime last weekend I finally started my engine rebuild today. I opened my shed to be greeted with this…

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1301215Medium.jpg

I then started cleaning up the Hylomar Universal Blue from the sump gasket and cleaning the threads for the sump bolts and oil pump.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1301217Medium.jpg

Then it was crank removal time and I gave it a clean as well as the block.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1301218Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1301220Medium.jpg

New shells in place for the crank.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1301221Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1301223Medium.jpg

Rear crank oil seal, it’s so much easier fitting this when the crank is out, a bit of grease and on it want.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1301224Medium.jpg

Refitted the crank and torqued down the mains.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1301226Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1301231Medium.jpg

Over she went for the piston fitting.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1301232Medium.jpg

Number one removed from the storage bag.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1301234Medium.jpg

You can see the rather deep pockets for the lairy SBC cams, inlet on the left exhaust on the right.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1301235Medium.jpg

In it goes with a little gently persuasion.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1301236Medium.jpg

Nice and snug at home once again.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1301237Medium.jpg

All pistons and rods fitted and new big end shells installed and torqued up.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1301238Medium.jpg

Further updates tomorrow when more bits get refitted…

[Harvey]

Didn’t get a great deal done today but it started with me cleaning the piston crowns and block face. I then fitted the ARP studs and head gasket.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1311213Medium.jpg

Head face cleaned and torqued down, it’s beginning to look like an engine again.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1311214Medium.jpg

I removed the water pump to check it and all is good and well so bolted it back in place with a new seal.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1311217Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1311216Medium.jpg

Now for the interesting part, the oil pump. As I’ve decided to opt for a Z20LET pump I knew I had some cut’n’shut work so here goes with the explanation. The later pump is designed for the later belt setup so there is an extra part on the pump housing for the lower idler that needs removing to get it to fit the early setup due to clearance with the back plate.

Here you can see the rear of the early back plate and original early C20XE pump.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1311218Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1311219Medium.jpg

The Z20LET pump doesn’t quite fit the back plate due to the extra casting on the pump.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1311221Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1311220Medium.jpg

It only looks like it’s a few mm that needs removing from one side but it’s mainly the depth of the casting that's the issue, you can see it more clearly below. Just remembered I need to get some longer M6 sump bolts for the oil pump as it uses M8’s so I’ll use M6 with washers and nyloc nuts.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1311222Medium.jpg

I started the oil pump cut’n’shut but it’s not finished yet as I had to pack up early today. On a good note I’ve bit the bullet and purchased welder so need to learn to weld now, watch this space as the crack on the lower o/s rack mount needs sorting before the engine goes it.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1311226Medium.jpg

[DarrenH]

great updates mate and pics :D

like the welder too, ive got the 165TE which is very similar specs, and its perfect for all our needs.

[Harvey]

Had the day off today so cracked on with the engine rebuild after doing a few jobs on the Calibra.

After my cut’n’shut on the Z20LET oil pump it looked like this. I didn’t want o remove too much so as to leave some strength.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2051218Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2051219Medium.jpg

When I checked the clearance to the back plate I noticed the right fixing was 10mm narrower than the early pump. Look to the right in the picture below, C20XE pump top and Z20LET pump bottom.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2051220Medium.jpg

Luckily I had some 10mm deep alloy spacers Keif made me for my bucket seats but I didn’t need them in the end so one came in rather handy as shown in the mock up below.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2051222Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2051224Medium.jpg

Trial fitted the oil pump, windage tray and sump to measure the depth so I could workout the M6 bolt length I needed for securing the sump.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2051229Medium.jpg

Oil pump fitted.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2051231Medium.jpg

The final turn doing the crank bolt up. Note the wood wedges I used to hold the crank, it’s so much easier with the engine out.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2051232Medium.jpg

Back plate fitted and torquing up the verniers.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2051238Medium.jpg

Spacer fitted for the back plate.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2051240Medium.jpg

Had this for about three years so it would be daft not using it.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2051245Medium.jpg

Timed up and double checked.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2051244Medium.jpg

Front engine mount, alternator fitted and pulley fitted. Also temporarily fitted the rocker cover and timing cover.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2051246Medium.jpg

I removed the Z20LET oil pressure relief valve for comparison with the SBC nylon C20XE version. Has anyone got a picture of the original metal C20XE relief valve?.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2051234Medium.jpg

[Keif]

Top work Mr.

Starting to look like a complete engine again.

Nice to see a bit of my handy work saved the day too.

Did you get my PM?

[DarrenH]

ha ! thats exactly how i did the crank bolt, old bit of floor joist between crank pin and block.

dont have a picture but the XE pressure relief valve looks exactly like the SBD one, but obviously metal.

[Harvey]

dont have a picture but the XE pressure relief valve looks exactly like the SBD one, but obviously metal.

The Z20LET relief valve must of been redesigned then. I'm now wondering if it's worth leaving it and not bothering with a SBD nylon one now, decisions decisions.

[laney]

if i was doing the same job, i would use the orig valve, but im not keen on the sbd valves anyway,

top job harvey as usual!

[Harvey]

Spent this morning finishing off the engine build as follows…

As I’m a bit anal I decided I was going to clean the sump bolts up prior to fitting so they went from this.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2061248Medium.jpg

To this

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2061249Medium.jpg

Then to this here

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2061257Medium.jpg

Here’s a dry mock up of the modded Frontera pickup and the gated and baffled windage tray. The pickup isn’t exactly central in the box but Matt who built it said it’s still doing exactly the same job.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2061255Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2061256Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2061253Medium.jpg

My highly recommended sump gasket sealer, top quality all the way and nothing else will do.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2061258Medium.jpg

Top face of gasket with sealer applied. You only need a small amount as it’s surprising just how much it spreads when torqued down.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2061259Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2061260Medium.jpg

All fitted so an arty shot of the oil pump end with M6 nyloc nut and bolt due to the M8 oil pump fittings. You can also see the 2x 1mm spacer washers I have used on each of the OE sump bolts due to me using the thinner 8v bonded gasket as apposed to the double cork gasket.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2061264Medium.jpg

Mocal oil filter thermostat fitted.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2061267Medium.jpg

All wiring fitted and new rocker gasket installed with all bolts tightened up.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2061268Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2061271Medium.jpg

All I have to do now it get it fitted after I have sorted the o/s steering rack mount welding, more on that tomorrow so watch this space.

[Keif]

:thumbsup:

[Harvey]

I didn’t get much done on Sunday due to the crap weather we had and having to do the car on my drive.

You can see the welding that needs doing.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2071213Medium.jpg

Here’s a better picture. I plan on doing similar to DarrenH and cut the mounting off, strengthen it from the rear and add some extra boxing and plating to the left to beef it all up.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2071216Medium.jpg

After cleaning up the gearbox, I still need to buy a gasket, I couldn’t resist a pic of the straight cut crown wheel and Quaife ATB…mmm, much loveliness and noise.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2071225Medium.jpg

[Harvey]

It’s been a while since I’ve done anything on the GTE as I’ve just been way too busy. So today I stripped the pedal box area in preparation for welding the cracked rack mount next weekend.

Brake m/c removed

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P3281239Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P3281240Medium.jpg

Then it was clutch and brake pedal removal followed by pedal box plate.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P3281242Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P3281241Medium.jpg

I managed to pull the wiring and bias adjuster cable that runs through the pedal box plate into the foot well and fortunately didn’t have to remove the dash carcass.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P3281243Medium.jpg

The wife lets me get away with most things but it was even better when she suggested I pop the GTE washer bottle in the dish washer to clean it up.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P3261237Medium.jpg

About 6 months ago I got hold of rarer than rocking horse droppings Eibach f+r ARB’s. The front is 23mm (standard 22mm on 16v) and the rear is 22mm (standard 18mm on 16v). I’ve now had them blasted and powder coated in purple to match their original colour. The front won’t make a huge difference but I’ll be leaving it loose anyway as John Cleland said it was a bit tight anyway and had slight understeer when he drive it at Knockhill last year.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P3261238Medium.jpg

[mick g]

:applause:Quality work as usual mate

[laney]

as mick said! lookin good mate, shame i cant spare the time, otherwise i would pop up and lend a hand with the welding, like i promised a while back :hissyfit: am far to busy with house stuff atm

[Harvey]

i would pop up and lend a hand with the welding, like i promised a while back :hissyfit: am far to busy with house stuff atm

Thanks Laney but I have to learn at some point so my mate is popping down who does welding for a living so I'm in good hands to learn how to 'glue' metal together :)

[astrayorkie]

:applause:some nice work there...

love arb's would like a front one of them

would this encourage understeer ?

[laney]

Thanks Laney but I have to learn at some point so my mate is popping down who does welding for a living so I'm in good hands to learn how to 'glue' metal together :)

cool! no worries mate, wish i wasnt so tied up with other stuff atm

[Harvey]

:applause:some nice work there...

love arb's would like a front one of them

would this encourage understeer ?

Your car will already have a front ARB fitted but the 16v came with a 22mm at standard other models came with either 16mm, 17.5mm or 20mm so might be worth looking for a 16v ARB and no my old one isn't for sale. They shouldn't induce understeer but hold everything nice and tight at the front under road conditions. My setup is that tight I need to give it slightly more roll on track so I'll either leave the front ARB loose, as I’m using using poly bushes on the drop links, or I'll disconnect it altogether. If it's too tight it'll cause understeer and strip your front tyres which is what’s currently happening on my car, as I was told so by the Astra mk2 God known as John Cleland.

I dearn't tell him not to lean on my car

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/TV%20shoot/Knockhill3.jpg

John giving my motor a good thrashing at Knockhill last Easter for the Total Vauxhall shoot, that's how come I know it's a bit tight on the front as he tried his best to strip the front tyres.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/TV%20shoot/Knockhill1.jpg

[astrayorkie]

i have one on my car already as is a 16v just wondered about the 23 mm uprated one what difference it would make.. as in my let astra used to understeer everywhere with the poly drops koni's so doing some investigating in to better setup's..

[Davey J]

I would have thought stiffening up the back and putting a thinner one up front on most GTE's would get the front to dig in more. Read about a SAAB ARB on here somewhere. Worth experimenting with the different thickness fronts instead of running without one? My friend ran a diesel front ARB on his GTE Nova years ago and a thicker one at the back. Said it improved turn-in loads.

[Harvey]

I'm already got the uprated Saab 22mm rear outer ARB (click for info (http://www.elkparts.com/saab-93-m98-to-02/suspension-system/components/upgraded-rear-antiroll-bargm900-93.p1751.html)) and with the Eibach inner 22mm bar the rear will be more than sorted. Going to have a think about front before putting a thinner bar, starting with leaving it looser than recommended might do the trick as the poly drop link bushes will allow for this.

Got a bit of welding done on the steering rack mount but after having a chat with a mate we now have a plan on how we are going to strengthen it properly, this will be done next weekend.

[Davey J]

It's worth emailing Tom Stickland about bulkhead strengthening if you get time to.........................

[Steve Heley]

I spent along time looking at how to make it alittle stronger without it turning into an eyesore. You can see from the picture i've put a strip in that pretty much fits on the end of the rack, i've also double skinned the same area on the inside and taken a bar from the cage to it (got no pics of that yet).

There's a few other cheeky little mods to spot.. Hopefully i'll start on it again this year as it's amazing how much 2 year old can put a stop to things :)

http://www.astra-mk2.com/steveheley/bay.jpg

[DarrenH]

excuse the crudity of the picture, i saw this setup on a race prepped mk1 golf on club gti years ago. (as in golf website) aim to replicate it on the gte.

the green lines represent thick wall cds tubing, red blobs are adjustable rose jointed links to the beam.

basically prevents the beam from distorting, and maintaining toe/camber. will also allow some fine tuning of toe.

http://www.darrenhilburn.pwp.blueyonder.co.uk/car_stuff/beam_mockup.jpg

will try and find the actual picture, need to trawl through the archive

[Harvey]

After researching the various repairs people have done on their o/s steering rack mounts I had a cunning plan in my mind so it started last Saturday. As “The Steg” (more on him later) and I decided the cracks in the mount weren’t that bad so we cut into them and welded them up.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4031246Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4031248Medium.jpg

Mission “weld it” then began on Friday evening with a cardboard template.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4091253Medium.jpg

Then some metal plates were made up using 3mm angle. I decided to use an Ian T design and plate the mount to the left stopping it moving up and down as well as side to side.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4091255Medium.jpg

We then also decided we needed to use some angle so we could pickup the inner wing to rack mount. So prepped the whole area for welding.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4101256Medium.jpg

Found a crack/split while cleaning up for welding.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4101259Medium.jpg

I fully admit I’m no welding expert, more of a welding virgin. So arranged for The Steg to come round who is a welding guru.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4101265Medium.jpg

Welding my crack up, oh err!!! Plus the obligatory welding FIRE!!!

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4101262Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4101264Medium.jpg

My the plating commence.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4101266Medium.jpg

Bit of a breather for The Steg.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4101267Medium.jpg

The welding done and tidied up. Had to make sure there was enough room for the rubber rack mount to slide into place when bolting the rack into place.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4101270Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4101269Medium.jpg

[Harvey]

Bit of seam sealer liberally spread on the welding and just about everywhere else. Also used some Master seal on the larger gaps to stop water ingress.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4101273Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4101275Medium.jpg

First coat of zinc printer.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4101277Medium.jpg

Final coat of rattle can glacier white. It’s not the prettiest but it’s no show car and you won’t see most of it when it’s all back together.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4101286Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4101296Medium.jpg

In between painting The Steg and I removed my engine from the stand and we fitted the flywheel and clutch. The clutch is a Helix four paddle version with genuine Vauxhall LUK pressure plate to keep it a nice light feel.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4101280Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4101281Medium.jpg

Improvised flywheel holding tool to stop it spinning when the bolts were torqued up and the final angle added.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4101283Medium.jpg

Clutch fitted.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4101284Medium.jpg

Now off outside to do some more refitting before the engine goes in on Thursday…

[Keif]

Nice update.

Got quite abit done too.

The Steg's a leg end, i'm assuming that you did some glueing too. :thumbsup:

[Danny]

Fantastic work as usual, Harvey.

[Harvey]

Been busy bolting bits and pieces back on today. Eibach front ARB, pedal box, bias box etc. Plan on getting the engine refitted on Thursday but working next weekend so it’ll hopefully be running next week.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4111305Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4111303Medium.jpg

Steering rack fits nice and snug.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4111309Medium.jpg

For anyone interested here a comparison of the OE front ARB (black) and the Eibach (purple).

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4111297Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4111302Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4111299Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4111298Medium.jpg

[Harvey]

All prep work now complete so engine is going in tomorrow evening...yippee!!!!!!!!!!

[ant]

Harvey great job didn't realise you hadnt done the firewall in the first build?

Some great fabrication there... you a fabricator by trade?

Darren keen to see this info on the rear beam... if you find it.

[Harvey]

Some great fabrication there... you a fabricator by trade?

Nope I'm not but I'm good with cardboard and sticky tape and The Steg is good with a grinder and welder....long live The Steg :)

I left 95% of the welding to The Steg as we just wanted it done righ first timet. I did the easy bits as I'm still learning with the welder.

I'm really really really really really really looking forward to ploking the engine in later...10 hours and counting before the work begins.

[Harvey]

YIPPEE…it’s in, just a few more bits and pieces before it’s all up and running.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4151312Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4151313Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4151314Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4151315Medium.jpg

Then it got dark…

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4151317Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4151320Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4151321Medium.jpg

[CavalierTurbo]

Well Done fella, nice to see it with a heart back in it. Just need to get it beating again. Whens she gonna be running???

[ste_goffy]

tomorrow if he gets his finger out lol

[Harvey]

I totally forgot in my excitment getting the pics posted last night so here goes...huge thanks to The Steg aka Ste for help with the welding and fitting the engine.

[ste_goffy]

There is no need for the thanks, just happy to help where i can.

[CavalierTurbo]

So did you get it running last night then mate?

[Keif]

Blimey, So Ste managed to get there to help refitting an engine. lol

[Harvey]

After another 4 hours on it last night I'm so close it's painful. List of jobs left before it loves once more;

Tighten manifold to system bolts
Bleed rear brake circuit (not essential to get it running)
Fill coolant
Fit battery
Standback and smile as it burts into life

I'll be on it as soon as I'm home from work today.

[Keif]

After another 4 hours on it last night I'm so close it's painful. List of jobs left before it loves once more;

It Loves you long time. http://www.thailantern.com/main/boards/style_emoticons/default/chinese.gif

Good work Mr. :thumbsup:

[Harvey]

Right some pics of work over the last few days

Painting the manifold with a couple more coats of VHT exhaust paint.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4161322Medium.jpg

Gearbox fluid being measured and slowly poured in through the top breather bolt hole. Thanks for the load of the filler bottle Andy, it was a great help.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4161323Medium.jpg

Yummy pink long life coolant, measuring out the 50/50 mix. 6.9 liters to fill the C20XE.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4181324Medium.jpg

Me giving the coolant a bj when filling

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4181325Medium.jpg

It looked that nice I gulped down what was left……if it didn’t kill you I would of.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4181326Medium.jpg

Oil catch tank, old on left new on right.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4181327Medium.jpg

Installed

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4181328Medium.jpg

It lives, was a bit tappety at first but cleared after 10 minutes. I’m well chuffed :)

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/th_The_GTE_lives.jpg (http://smg.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/?action=view&current=The_GTE_lives.flv)

[CavalierTurbo]

Well Done Harvey, A quality catch tank there, So whats left to do? Is it booked in for MOT yet. ha ha.

[ste_goffy]

There cannot be too much left to do now surely.

All worth it in the end.

[Harvey]

All done now so hoping to get MOT sorted for next week :thumbsup:

I managed to bleed the rear brakes without lifting the back, bit fiddly but I did it.

[Harvey]

It went back on all fours last night so I had my first drive since June last year, well, I say first drive but all I did was turn it round on the drive. The handbrake has been on for nearly a year and it hadn’t seized which amazed me.

Engine bay all back together

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4191338Medium.jpg

Interior complete once more

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4191332Medium.jpg

My god I forgot just how good it looks

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4191334Medium.jpg

I also ran a compression test after it had been running for a while and up to operating temps. All were around the 18 bar mark so spot on for a high compression engine as I remember it was around a similar figure for the engines previous build with the C20XE oil pump.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4191341Medium.jpg

I've now got to figure out how to setup the Shift-i (shift light) as it's not straight forward due to all the features the unit has.

[laney]

it doesnt look good mate, i would say it looks the bollox! very nice mate, although i do say that alot, lol

[Davey J]

And I jizzed in my pants

[Harvey]

Steady on chaps as it's only a bit of metal..but it's my bit of metal and I love it :)

Insurance is now sorted as Adrian Flux have come up trumps yet again and the MOT is booked for 10:30 on Monday so wish me luck. If she passes I plan on collecting the Tax a week on Sat 1st May otherwise I'll loose nearly a month.

[ste_goffy]

then maybe a drive over to ours to give it a good but close run????

[CavalierTurbo]

Not before he's been to mine for me to druel all over it again. ha ha

You got that shift light wired up yet??

[Harvey]

You got that shift light wired up yet??

That's tonights job as I fitted the rear Eibach ARB last night but not had chance to update the diary yet.


then maybe a drive over to ours to give it a good but close run????

To be sure sir ;)

[Nova Ian]

Hey nice one Harvey, good to see it all back together and on its wheels again... Glad it all went smoothly.

I think you need to give me a hand with the nova! lol

I'll look forward to seeing yourself and the beast at some point this year

[Harvey]

I'll have to pop over Ian and have a closer look at yours as I need to run it in. First things first I need an MOT so I hope it passes on Monday.

[Harvey]

Fitted the rear Eibach ARB last night so pic below is the old bar removed from the beam. Came out a lot easier than expected, WD40 is my best friend.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4211241Medium.jpg

Old and new compared

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4211242Medium.jpg

Thickest part of the old bar is 19mm and the thinnest 17mm, new bar is 22mm all round.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4211243Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4211244Medium.jpg

Slipped in a treat. You can see the uprated 22mm outer Saab 95 bar in the pic.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4211245Medium.jpg

I had to Dremel out the centre bush as it was way too small for the new bar. G-clamp and WD40 got it fitted in no time.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4211249Medium.jpg

Tonight I tie wrapped up a few bits and pieces and fitted some nice new stickers to my pedal box as the permanent marker was no more.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4221258Medium.jpg

[Harvey]

On holiday today and had the MOT on the GTE at 10:30…

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/Image186Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/Image188Medium.jpg

…and….it passed :). Just need the TAX now which I’m collecting on Saturday otherwise I’ll loose a months worth.

[Nova Ian]

I'll have to pop over Ian and have a closer look at yours as I need to run it in. First things first I need an MOT so I hope it passes on Monday.

I'll hold you to that! Would be nice to see the astra running as i've only ever seen it on your drive and at Billing.

Glad to see its passed the MOT, although I didn't doubt that it would as its deffo in good shape

Ian

[ste_goffy]

Maiden voyage done and all was well,

Thanks for coming down, and oh you forgot you little bag of goodies.

[ant]

Looks good Harvey good to see it back together and running... bet that feels better.

Don't mean to be an alarmist Harvey but I never allow anyone to jack my car by the middle of the suspension like that. I have seen them with a slight bow after being jacked up... mind you it was a station wagon or estate as you chaps call them, so yes they are much heavier but still I never take the risk.

[Harvey]

Ant I have always jacked the rear using the beam and then use axle stands under the chassis, which you can't see in the pics. Never had a problem at all.

My dad popped and collected my tax last Sat and I had my first run out last Tuesday evening, my god did it feel good and no leaks which is a bonus. Got it booked in for tracking tomorrow as the steering wheel is slightly off and I don't want to rip the R888 to bits so better to be safe than sorry.

Also been looking into smaller alternators and managed to bag myself a bargain after scanning through MIG for sale yesterday. An SBD purchased ultra small Dippon Denso 2-wire alternator 2.5kg 50amp. Very little use and two thirds the price of SBD. Should be arriving next week so in the mean time I'll order the SBD fitting kit for it as I can't be bother calling round to source my own bits so I'm going to cheat. More info here (http://www.sbdev.co.uk/Electrical/Alternators/2L_Alternators.htm) on the SBD site.

http://www.corsasport.co.uk/carimages/1368/dsc00156.jpg

[mph]

Good 2 see it's up and running again. Nice find on the alternator, wish i could find one! Let me know what trackdays your thinking off

[ant]

Ant I have always jacked the rear using the beam and then use axle stands under the chassis, which you can't see in the pics. Never had a problem at all.

Good to know... I won't panic if I see it again.

My god that alternator is small... good find.

[Harvey]

So far so good as I've now covered 103 miles and all is well with the GTE. Been taking my time and not giving it the full beans only taking it up to 5K maximum. Amanda had a drive yesterday and quickly remembered just how heavy the quick rack is as slow parking speeds, lol. Got it booked into Noble Motorsport (www.noblemotorsport.co.uk) on 1st June for a health check but need to cover a few hundred more miles and do an oil change from the Vauxhall semi-synth to the Millers CFS 10W60 (http://www.millersoils-online.co.uk/M3_cgi/millers2.cgi?product_id=26&exact_match=on&type=motorsport&cart_id=).

[Harvey]

Just received my Denso light weight alternator today and my god it’s small. It also came with a 1.4/1.6 mounting kit which is no good for my engine so I’ll sell it on meaning my alternator will of cost even less than what I paid, bargain. Been hunting round for a wiring guide and found this, Denso wiring instructions (http://westfield-world.com/daihatsu_alternator.html). It’s the type 1 that I have but I believe I don’t need the switched live feed. SBD also kindly supply fitting instructions for their mounting kit here (http://www.sbdev.co.uk/Info_sheets/Alternators/Fitting%20SBD%20alternator%20adjuster.htm). As you can see the kit looks easy to make but I really couldn’t be bother messing about so have purchased the kit.

2.75KG, not bad for an alternator

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5111263Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5111264Medium.jpg

It's ikle

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5111265Medium.jpg

The rear wire connectors and main battery post right

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5111267Medium.jpg

[iansri]

How much does the standard alternator weigh ? & whats the total weight saving

[Harvey]

How much does the standard alternator weigh ? & whats the total weight saving

I'll let you know when I swap them but I would guess it's almost double.

[Harvey]

Was out and about in the GTE last night and found I had a ikle oil leak on the front n/s of the sump. Going to investigate further tomorrow morning. I can't believe it as I sealed it properly and torqued it down, oh well (does a big sigh and shrugs shoulders).

[Harvey]

Had the GTE front end in the air yesterday so I could have a closer look at the oil leak. I can only assume I didn’t use enough Hylomar Blue when I sealed the baffle plate as it seems to be weeping out the front. I’m not planning on resealing the sump this soon as I’ve only covered just over 200 miles so that’s a next Winter job. I’ll just keep a close eye on things down there for this year. I did remove each sump bolt one at a time and used loads of Hylomar on each in the vain hope this might help.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5151263Medium.jpg

While I was under there I checked everything else and notice a couple of small splits in the CV boots o/s outer and n/s inner.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5151265Medium.jpg

So after some nut removal and swearing, I have doing CV boots as the grease gets everywhere, both were wearing new rubber.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5151266Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5151268Medium.jpg

[CavalierTurbo]

There is always something to be done isn't there.

[Harvey]

There is always something to be done isn't there.

Your so so right Andy.

Ran the GTE up to temp last night and all good with no oil spotted escaping, I bet I'll show it's ugly side when I next drive it though.

[DarrenH]

those sump gaskets really are fussy buggers. i mean, its not like its pressurised to 80 psi like the oil pump and switches. all it has to do is stop the gravity of the weight of the oi,l and it still finds a way out

[James C]

My gearbox doesn't leak any more and nor does the petrol hose, oh an nor does the rear quarter windows. Thats about all that doesn't leak though. MK2 astras for you!

[Harvey]

Had a small parcel arrive yesterday

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5181265Medium.jpg

SBD Denso 2.0L alternator fitting kit

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5181266Medium.jpg

Not much to it to be honest but as least I can now crack on with fitting it

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5181267Medium.jpg

[CavalierTurbo]

Well if it arrived yesterday, why isn't it already fitted. Come on man pull your finger out lol

[_SBD16v]

those sump gaskets really are fussy buggers. i mean, its not like its pressurised to 80 psi like the oil pump and switches. all it has to do is stop the gravity of the weight of the oi,l and it still finds a way out

But it's even worse than that the oil line is well bellow the sump join

[Harvey]

Friday night was time to fit the Denso alternator so I set about figuring out where I was going to get an ignition feed for the voltage regulator. After a quick flick through the Haynes I found that the reverse switch for the gearbox had a dedicated fused (fuse 13) ignition feed so a plan was formulated.

I started by stripping the sausage filter, trumpets and back plate for ease of access. More on that later.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5211318Medium.jpg

Next up was to remove the engine wiring harness.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5211311Medium.jpg

Then I needed to find the reverse switch ignition feed.

Second row down on the right.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5211313Medium.jpg

Second row up on the right. Thin solid black as the thicker solid black is the engine management ignition feed which isn’t fused.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5211314Medium.jpg

Then it was time to strip the tape off the harness and insert an extra thin black wire in. I used a wire I chopped out the original GTE main car loom so kept it OE fitment.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5211324Medium.jpg

I decided the best thing to do was solder the feed just before the reverse switch feed came off the loom.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5211325Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5211326Medium.jpg

I then cut the original battery warning light connect off and found an old GTE loom plug that just fit the Denso connection so set about yet more cutting and soldering. Then I ended up with this so taped up the loom and re-fitted it.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5211327Medium.jpg

Next up was to remove the original alternator and weigh it. I ended up lowering the original alternator out the bottom of the car next to the exhaust as it just wouldn’t come out the top way.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5211328Medium.jpg

Not as heavy as I first thought 4.875KG

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5211329Medium.jpg

Denso weighs 2.775kg. I know I said 2.75KG the page before so it’s there abouts as the scales aren’t brill. That’s just over a 2KG saving so every ikle bit helps.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5211330Medium.jpg

Big brother & little sister.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5211331Medium.jpg

Fitting the Denso was easy and I was able to feed it down from the top and under the inlet fanny mould. I now need a new belt as the one I have is 45mm too long. I’ve measured it up and I’m looking for a 800mm long belt so off to my local Motor Factors so see my mate today.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5211334Medium.jpg

[Harvey]

800mm belt purchased and installed. Tested the ignition but no battery light so further investigation required when I get the time.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5221267Medium.jpg

[Belmont turbo]

whats the advantage of the denso altinator? is it just thats its smaller and lighter? what amp is it?


when i did my sump with the 8v gasket i didn't use and sealent just locktight on the bolts and it dont leak at all! gear box dose tho :(

[DarrenH]

not trying to teach granny to suck eggs, i didnt know how alterrnators work, this was posted on another forum i use, a couple weeks back...


When the ignition is switched off there is no feed to one side of the battery light, the other side is connected via the field windings (rotor) and the regulator, to the output of the alternator. It is taken as read that you understand the output coils of the alternator are connected between the output terminal and the alternator case, then via the engine block and earth straps to the Battery Earth Terminal (negative).

What this means is that when the engine isn't running the warning light is connected, via the alternator field windings, plus regulator, plus output windings, to earth. ... OK? Don't skip over that point.

When the ignition is switched on, 12 volts positive is fed to the switch side of the light, the other side of the light is at earth (via the field windings etc as just described).

The flow of current, through both the lamp and the field windings, lights the lamp and creates a magnetic field around the field windings (rotor).

As the alternator spins, this rotating magnetic field produces a voltage in the output windings.

When this reaches sufficient strength via the regulator to 'self-excite' the rotor, the voltage on the lead to the warning light reaches 12 volts, or whatever voltage is also being fed to the battery.

The warning light now has '12' volts from the battery via the ignition switch on one side, and '12' volts from the alternator on the other side. Because there is no difference in the voltages across the bulb, no current can flow through it, and thus the bulb doesn't glow.

[Harvey]

Thanks for that Darren, I knew the basics but that helps so I hope others benefit from the info as I have. Earthing is fine on the alternator and I'm getting the 12v feed to the alternator from the light feed blue/white wire when ignition is on so need to check the loom plug at the alternator but not had the time just yet.

[Harvey]

Had 20mins on the car and found that I only have 2.4v at the alternator for the battery light feed when connected. When disconnected it's got 12v so it must be the alternator, oh well. Luckily I have a built-in battery monitor on the shift light so I'll live with the battery dash light not working. Tested the change from the new alternator and it's fine so all good and well there.

Next issue I've found is that after starting the car today the FPR is making a very very loud whine but is holding pressure. If I tightly hold the FPR the noise goes away so I can only assume it's on the way out, possibly diaphragm. Can anyone recommend a proper decent motorsport FPR as I'm currently running a FSE Black top FPR.

[Harvey]

As I believe my FPR is on the way out, not entirely sure so taking no chances, I've just ordered a new Sard reg and gauge from the eBay shop CustomizeCarWorld (http://stores.ebay.co.uk/CustomizeCarWorld). I've read about copy Sard regs doing the rounds but these seem genuine so I've taken the chance and bought one this morning. Fingers crossed it arrives before the end of the week as the GTE is booked in for a health check next Tuesday.


Evening update:

Checked all the nuts and bolts that hold the FPR together as well as the mounting bracket fixings and tightened everything up. Started the car and no more whine from the FPR. I can only guess the mounting bolts had worked ever so slightly loose and the solid engine mounts coupled with the flex in the top of the bulkhead and pulsing from the fuel pump was causing it to resonate violently. Strange how it just started doing it and didn't progressively get worse and worse. Anyway I'm glad I ordered the Sard FPR as I'll have a spare as I believe the FSE motorsport one I currently have fitted has seen better days but it'll do for now so I'm going to leave it in place.

[Harvey]

Popped out in the GTE today to check for oil leaks and the strange FPR noise. I’m pleased to say neither appeared. It’s now raining and I didn’t get time to stick my cover on it so it’s looking sorry for itself on the drive.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5261308Medium.jpg

At least it’s beading well. I’ll give it a dusting over tomorrow and get it covered when I get home from work.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5261309Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5261312Medium.jpg

[Harvey]

Covered the mileage I wanted to before the engine check over yesterday so Monday I changed the Vauxhall semi-synth for the Millers CFS 10w60. It was a shame to discard oil that had only covered 300miles.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5311308Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5311309Medium.jpg

Had a bit of a spill but all cleaned up now thanks to some magic Betterware oil spot remover.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5311310Medium.jpg

Next up was to check the battery warning light that wasn’t working. I admit it, I’m a retard as it’s been working all along due to it being built into the LCD part of the GTE dash, my god how stupid do I feel.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5311325Medium.jpg

I also wired in the brake fluid light to the battery warning light so when you turn on the ignition you can test the brake fluid light confirm it’s working. I have rewired the hand brake to its own light and the brake fluid light to a separate one. All good and working as I want now.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P5311326Medium.jpg

Also glued my o/s headlight cover as it had a huge crack in it and it was getting bigger and bigger.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P6011330Medium.jpg

Now onto the good news as my GTE had a trip to Noble Motorsport ( http://www.noblemotorsport.com/) in Chesterfield this yesterday where I had it mapped back in October 2008.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P6011328Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P6011327Medium.jpg

The power graph from today 220bhp and 162ibft so spot on and exactly what I was expecting, I’m over the moon all is well. The run below was done in 4th gear with a max speed of 112mph. I was told the FPR was a tad too high so they turned the fuel pressure down a touch under 3.5bar, I’ll keep an eye on it over the coming months. I had a few guys there tell me how nice the GTE was which is always pleasing due to all the hard work and effort I’ve put into it.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/Nobles_01062010.jpg

[ant]

Fantastic.... over the moon would be an understatement.

[_SBD16v]

I'm running the small aeromotive fpr works well

[Harvey]

I'm running the small aeromotive fpr works well

Thanks Rob, I did look in to the Aeromotive FPR. They are a good bit of kit. I've sold on my SARD one I purchased as mine is fine now and making good pressure with no funny noises. I think it was me just jumping before investigating properly.

[Harvey]

I’ve had a spare polished belt cover for ages now which had some inaccurate pulley holes cut into and so I thought I’d do something different. I marked it up how I wanted it cutting and gave it to a mate (thanks Keif) to cut properly.

This is how it was returned to me.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7021374Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7021375Medium.jpg

It was then wiped down and a couple of coats of primer added.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7021377Medium.jpg

Before a few top coats the day after.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7031387Medium.jpg

Once dried it was time to fix the 6mm perspex into position. It had the raised texture removed from the rear so it would sit flat.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7031391Medium.jpg

Perspex in position.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7031390Medium.jpg

Then using some white Silcoset it was bonded into position and left to dry. I did plan on using small rivets but it looks so much better without any fixing showing. Silcoset is good for up to 600oC so should be fine, I’ll just keep an eye on it.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7031392Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7031393Medium.jpg

Then it was fitted, much better :) I'll get an in-action shot later today, bit early to fire it up at 07:30 on a Sunday morning.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7031404Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7031406Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7031402Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7031407Medium.jpg

[Harvey]

Nice ikle vid of the new window.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/th_Pulleys.jpg (http://smg.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/?action=view&current=Pulleys.mp4)

[Astranomical Lee]

A nice little easy mod which makes a massive difference. I think that looks really smart.

[Harvey]

I love it but as I keep saying to everyone "it's not a show car". However it didn't stop me giving it a wash, polish and wax on Tuesday ready for Billing. I've even done a rather posh photographic full build album so pop over to the Vauxhall Drivers Club (www.VXdc.co.uk) stand and have a look.

[Anthony]

Looks good Harvey :thumbsup:

I've now got some enthusiasm to finish mine again now, trouble is i've sold most of the bits :bigcry: Thinking of keeping it NA this time (wanna sell that engine? lol)

How are getting on with the HiSpec brake kit though please mate. Stupidly i sold my Reylands, which tbh, i couldn't fault them, worked a treat.
Just can't decide whether to get the another reyland kit, or give the 300 hispec kit a go??

Regards
Anthony

[Harvey]

How are getting on with the HiSpec brake kit. Just can't decide whether to get another reyland kit, or give the 300 hispec kit a go?

I can't fault them to be honest. I'm running Mintex M1144 and they work fine on the road but once warmed up on track they are awesome and just get better and better. Mick G is also running the HiSpec (don't know which pads) but with OE servo so you might want to ask his opinion as well.

[Danny]

I had Mintex 1144 pads back in the day.

Obviously yours Harvey are a more improved design, but even back in the day they were superb and meant when I was racing my mates I could out brake them.

Deffo recommend Mintex 1144 pads.

[Harvey]

It made it there and back to Billing which was a bonus. Checked it over when I got home and found I had a split inner CV boot. I’ve replaced two boots recently with stretch boots, installing them the proper way and not stretching them. Both have now gone faulty after minimal use and had small splits in them. Popped to my local Vauxhall stealers and they wanted £20 for an inner boot kit, how much! I'm not tight when it comes to spending on the GTE but £20 is just silly for a boot kit. My local Motor Factors have come up trumps and are getting me in a proper boot kit for £8.

Drive shaft removal

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7201417Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7201418Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7201419Medium.jpg

Sexy Quaife ATB shot

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7201424Medium.jpg

The offending boot

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7201420Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7201421Medium.jpg

Also popped to my local Millers supplier and after a bit of bartering got a cracking deal on 4x 5ltr tubs of CFS 10w60. Worked out to £37.50 per 5ltr not bad to say Demon Tweeks is £64 + p&p and even Opie is £46 member price + p&p.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7201413Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P7201415Medium.jpg

[Harvey]

My Brise starter motor has been playing up this year and a few times has required assistance with a tap on the solenoid to get it to turn over. I contacted Brise directly who have been superb and offer free technical assistance. After having a chat with one of the guys there a new solenoid was on route and it arrived the next day. It’s now fitted and I just need a dry evening to get it installed and tested.

The offending Brise starter.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P8241525Medium.jpg

Faulty solenoid.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P8241526Medium.jpg

Removed.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P8241527Medium.jpg

Bit dirty in there so I wiped it out.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P8241528Medium.jpg

Old on left new on right.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P8241529Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P8241530Medium.jpg

Some of the bits that the solenoid pushers to engage the starter.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P8241531Medium.jpg

New solenoid fitted.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P8241533Medium.jpg

[Harvey]

Finally had 20 mins spare yesterday morning to get the starter fitted. Seems to be working fine now so time will tell if the new solenoid has fixed the problem.

[Harvey]

Popped my Winter storage wheels on the GTE yesterday and as the weather was nice took it out for a spin as I’ve not driven it for about 6 weeks. It was nice to give it a blast as I forget just how nice it sounds and drives. Not had the time to book any track days as so much else going on so might do something November time.

Winter rims OZ magnesium in 15”x7” ET49 with Toyo T1-R 195/50-15.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P9181483Medium.jpg

Compomotive TH on the left and OZ on the right. A very similar wheel when compared side by side by the TH just have that classic look about them, however the OZ as a few kilo’s lighter due to being magnesium.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P9181486Medium.jpg

And fitted…mmm they look nice even if I do say so myself.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P9181488Medium.jpg

[laney]

lookin good as always mate, wish i had some spare time for my car, at work atm, lol

[Harvey]

I can report I no longer have the sticky starter motor issue which is a bonus. Popped out in the GTE on Sunday and it was a pleasure to drive it again as it had been a while. I forget just how quick the thing is!

I've purchased a little something from a member on another forum and I intend on fitting it next year to see what, if any, gains I might get. Will post pics later today...

[Harvey]

I received a large light weigh box earlier this week

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PA151574Medium.jpg

When I open said box I found this

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PA151575Medium.jpg

When unpacked it looks like this

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PA151576Medium.jpg

When connected it’s like this

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PA151579Medium.jpg

A fellow Vauxhall Drivers Club (http://www.vauxhalldriversclub.co.uk/vxhome.php) member was having a clear out and had a brand new SBD Astra mk2/mk3 TB airbox setup he had intended on using on his Astra mk3 but the ABS pump was in the way and has since sold the car. It’s got a cut-out as you can see below to clear the master cylinder and I’m hoping I’ll just be able to squeeze it on my setup with the twin pedal box. The SBD site blurb here (http://www.sbdev.co.uk/Air_Filters/Air_Boxes_Backing_Plates/Air_Boxes_Backing_Plates.htm)states I might not gain anything but I thought it was worth a punt at the price I was offered it at so it’s now stashed in my loft so I can play next year. I’ll just need to make an alloy back plate for it which is no sweat at all.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PA151577Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PA151578Medium.jpg

[DarrenH]

ah ! it will be interesting to see what happens. gary ran one of those on those very throttle bodies in the pineapple mobile.

[Harvey]

It's now SORN as I thought I'd get the cash back on my tax as I can't justify using it one day a month for my local meets. I will miss it but cash in my pocket is better then only a few hours use over the next 6 months.

[BlackBox]

That's an interesting looking airbox Harvey, Please let us know how you get on with it when the time comes.

[mick g]

If it doesnt fit H let me know as i'm getting set up with the kit to make things from Carbon Fibre... Could knock something up

[Harvey]

After being off the road for Winter I've been doing some investigation work as my insurance renewal is due next month and Adrian Flux were the only place that would help last year due to the modifications. So much for all these other 'specialist' insurance companies, as soon as you mention roll cage and no back seats they don't want to know you. I know AF will be a similar if not higher figure than last year so I tried a local motorsport specialist insurer and they have come up trumps with a quote at nearly half the premium I paid last year. All modifications are covered and the only thing not the same as AF is they don't offer agreed value, which I can live without. So if you have a car with a roll cage and no back seats why not give Richard Egger Insurance Services a try at www.reis.co.uk

[DarrenH]

try these guys

http://www.heritage-quote.co.uk/

they are insuring my red gte at just under half the price it was at flux last year (260/540 respectively). got it capped at 3k mileage from memory, break down cover, legal expenses, track day cover included (big excess though)

[Harvey]

Thanks for the info Darren. Heritage quoted me less then Flux on a classic policy but still not as cheap as Richard Egger so I'm going with www.reis.co.uk this year which saves me enough to cover 6 months Tax and the MOT :)

Now my Project Shed (http://www.astra-mk2.com/forum/showthread.php?30965-Project-shed-the-wooden-variety) is complete I thought it was time to dig the old girl out of Winter hibernation so I popped to collect my Tax last Friday and took her for the first spin of 2011 up to see RallyMarshal (Paul) on Saturday evening. I forget just how quick it is until you get to do traffic light GP starts and leave everything in your wake......it just makes me giggle like a school boy.

Looking spunking in the 2011 sunshine

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4021978Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4021977Medium.jpg

[Spankee]

That just looks lush love those rims great heads up on the insurance mine is up next month will give them a call :)

[laney]

she does look the dogs bits mate!!! and i know exactly what you mean @ traffic light gp!!! and i also grin like a school boy, its naughty but fun :)

[Harvey]

Had a bit of a win win with my insurance today. I called Flux up with the REIS quote I got last week and they have beaten it by £5 so I'm still with Flux and saved a total off my renewal of...wait for it...£145. When I asked did they want to be sent a copy of the REIS quotation they said no. Just goes to show what can be done if you call round come renewal time and top marks for Flux as I'm staying with then for yet another year.

[DarrenH]

how can they do it ? i dont know any other business that gets away with indiscriminately overcharging in the first instance.

[himselfunknown]

I refuse to use insurance companies that overcharge in the first instance, on the basis that they would have happily robbed me had I not spent more of my time and money phoning them to get the price down. If the renewal quote isn't the best they can do, for a 'valued customer', then I don't want to know.

On topic, tha Astra is looking as sweet as ever. Planning on showing it at all this year? I didn't make it to any shows last year, so I'm hoping to make it to at least one this year, and this car is one I definitely want a look at.

[Nova Ian]

Looking great as always Harvey, Hopefully have the nova out this summer so let me know if your thinking of any trackdays! Its going to be setup early may time hopefully, so fingers crossed everything goes ok with that and should be out there : )

Great news on the insurance and the new shed, your old one is still in storage at the mo! lol, should get it up this year though, one of many jobs that needs doing!

Ian

[Harvey]

The car will be at Billing from the Friday to Monday on the VXdc (Vauxhall Drivers Club) stand, sorry Astra-mk2.com but I'll be displaying with a few other mates who own other Vauxhall models. I learnt my lesson after last year as it's a little too long to drive it there so I'll be cheating and trailering it down. It's no fun driving a bean can that is very loud and very warm inside.

[Harvey]

GTE flew straight through the MOT today with no issues at all, I should hope not as well as it's done less than 900 miles since the last one ;)

[DarrenH]

ear plugs or ear defenders cure that tiredness. or go one more "motorsport" and get an intercom system!!

as for the MOT congrats, but as we all know even if you did zero miles its still enough to get "play in offside rear wheel bearing" :D

[Danny]

Lol at Darren's response which is so true!

Nice one Harvey. The car is an absolute cedit to you.

[Harvey]

Not done anything to the GTE apart from clean it a couple of times, god dam brake dust and flies. However I did pop to a local show on Sunday 22nd March and to my surprise I won a rather nice trophy for my hard work. I’m well chuffed as you can imagine.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Misc/P5262064Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Misc/P5262065Medium.jpg

[DarrenH]

pics or it didnt happen !!!! lol

[BenH]

Great car! Just a question about your brakes do you find you use the bias valve at all? As I have both a pedal box and a bias valve and I cant remember if I used both at the same not or if I just used the bias valve on it's own before I got the box. It's been a long time since I had them on car and just starting to put this one together thanks.

[Harvey]

Ben I only installed the rear in-line bias as I was finding I had to wind the pedal box bias all the way to the front. I've now realised that I had the front and rear master cylinders the incorrect way round as the smaller bore should be used on the fronts as it offers more pressure.

[Harvey]

To keep this diary up to date I've copied a forum post from the General section dated 2nd October 2011.

After a post on the forum by Paul (RallyMarshal) on Tuesday regarding a late scheduled trackday at Blyton Park organised by www.javelintrackdays.co.uk I thought sod it I’ll do it. Main reason was after doing service crew for Paul last weekend and not getting the GTE on track so far this year I thought it was about time that I pulled my finger out as the motorsport bug was there.

I spoke with Paul on Wednesday and he basically said if I booked he would, so I did and he did. Paul had just enough life left in his brakes and tyres after the Woodbridge stages to manage a single track day. My GTE was fresh as a daisy as it’s only covered 332 road miles this year so it was about time it had a good drive on track. The track in question was at Blyton Park (http://javelintrackdays.co.uk/trackday/index.php?option=com_content&view=article&id=119) a new tarmac 1.6 mile track laid on the old airfield. This is the track BazW had a session at a couple of weeks ago and loved it, more about him later!

Blyton PArk 1.6 mile circuit.

http://www.javelintrackdays.co.uk/trackday/images/stories/venues/Blyton_trans400.jpg

The day started at 06:30 leaving the house with car, wife, tools, fuel etc. We then met with Paul, Wife and neighbour called Paul (I'm easily confused) on route at 07:15. Arrived at venue near Gainsborough at 08:15. Unloaded cars, signed in and had a drivers briefing and then the wife drove with me as passenger for three sighting laps. I then jumped in the GTE and went and had a very enjoyable 6 or so laps as did Paul in his wobbly rally beast.

After I came in Amanda (the wife) and Ali (Paul’s wife) jumped in and Amanda headed out for a drive. A minute or so later we all noticed a yellow flag being frantically waved at the pit line entry. After glancing over I spotted the GTE stopped just off track to the right. It was quickly recovered and brought back to the pits. Amanda had managed a whole 100m on track but when going for 2nd gear the gear linkage pivot ball had broken so the car was stuck in neutral. On closer inspection it had obviously started to go before she jumped into the car but just ‘happened’ to break when she was driving, lol. The real kick in the balls is that it had crossed my mind to change this quick shift pivot linkage for a stock item a couple of weeks ago as I had been struggling to select all gears effectively for some time and especially 3rd as I kept missing it on hard driving.

Pic of the offending broken item.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Blyton_trackday_%20Oct_%202011/PA022441Small.jpg

After a couple of minutes of head scratching and the sinking feeling that the day would be over for the GTE I made a call to BazW as I thought he might have a spare stock linkage I could borrow and it was closer to get to him than to pop home. After a quick chat with Baz on the phone and a 2 hour return drive it was fixed and the GTE made the afternoon session. Huge thanks go to Baz and his poorly mk3 GSi that donated it’s linkage for the day. If it wasn’t for Baz I would of lost even more track time so thanks again dude.

Some more pics and vids from the afternoon.

Checking the car and setting up the linkage.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Blyton_trackday_%20Oct_%202011/PA022445Small.jpg

Paul felt the rear end of his would be better with a lower stiffer rear spring so I lent him Amanda’s Eibach’s which are destined for her Astra mk3.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Blyton_trackday_%20Oct_%202011/PA022449Small.jpg

The springs helped a lot and tightened the backend up no end.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Blyton_trackday_%20Oct_%202011/PA022466Small.jpg

My GTE felt fantastic and with the stock pivot linkage fitted changing gear was much better.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Blyton_trackday_%20Oct_%202011/PA022457Small.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Blyton_trackday_%20Oct_%202011/PA022462Small.jpg

Both on track at the same time. Paul was flying in his ikle 1400cc and my god did it handle well. I had a drive of the rally motor and loved it to bits, I was so impressed with the engine performance it’s a credit to the engine builder.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Blyton_trackday_%20Oct_%202011/PA022477Small.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Blyton_trackday_%20Oct_%202011/PA022475Small.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Blyton_trackday_%20Oct_%202011/PA022480Small.jpg

Couple of vids, poor quality but you get the idea of the fun we both had. Click the picture to play.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Blyton_trackday_%20Oct_%202011/th_RallyMarshal_Blyton_Oct_2011.jpg (http://smg.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Blyton_trackday_%20Oct_%202011/?action=view&current=RallyMarshal_Blyton_Oct_2011.mp4)

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Blyton_trackday_%20Oct_%202011/th_Harvey_Blyton_Oct_2011.jpg (http://smg.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Blyton_trackday_%20Oct_%202011/?action=view&current=Harvey_Blyton_Oct_2011.mp4)

It was all over at 16:30 so we loaded up.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Blyton_trackday_%20Oct_%202011/PA022492Small.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Blyton_trackday_%20Oct_%202011/PA022497Small.jpg

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Paul’s fleet of Skodas rock, VRS ‘R’ US and our trusty bus.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Blyton_trackday_%20Oct_%202011/PA022500Small.jpg

[Harvey]

As it was Christmas Eve and all the festive preparations were complete I thought I’d give the GTE some Harvey time.
After it hadn’t been ran for three months I warmed it up so I could drop the oil and replace with some fresh as well at a nice new oil filter.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC242633Custom.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC242632Custom.jpg

I then removed all four wheels so I could spanner check everything.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC242636Custom.jpg

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Then it was time sort the brakes as my master cylinders required swapping over. I had initially thought that the larger bore .700 was for the front and the .625 was for the rear. However this is incorrect as the smaller bore offers more pressure so needs going to the front and the larger bore moved more fluid but offers less pressure so goes to the rear. I had always wondered why I had the balance bar wound all the way to the front d’oh!

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC242638Custom.jpg

The fluid was drained using my Eezibleed and had lost a little of its strange purple colour. I guess it’s just a dye added to the fully synthetic fluid, more on that later.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC242650Custom.jpg

Using my trusty brake pipe spanner the unions at the master cylinders came out without fuss.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC242652Custom.jpg

The cylinders then just unbolted and the push rods unscrewed from the balance bar once the lock nuts were loosened.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC242655Custom.jpg

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http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC242660Custom.jpg

In traditional Haynes manual style, refitting was the reversal or removal. Note to self, swap over the Front and Rear master cylinder labels.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC242662Custom.jpg

It was then time for some fresh Automec fully synthetic fluid, it’s awesome stuff and comes highly recommended. If you have a car that doesn’t get used much I recommend you stick this stuff in for your brakes and clutch fluid as it doesn’t attract moisture and never requires changing. I added the stuff I removed back into my top up bottle after filtering it through some tights. I then gave it a mix with the new stuff and bled the brakes. The fresh stuff is an awesome colour as you can see. I guess the colour is just a dye so you can spot any leaks but I might be wrong.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/PC242663Custom.jpg

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[Roger]

nice technical review... love it..

[DarrenH]

nice work again harvey. i guess the master sizing also scales with the slave or pistons in the calipers themselves. if you had giant 6 pots (extreme example) youd need a bigger master to shift more fluid

[BenH]

nice work again harvey. i guess the master sizing also scales with the slave or pistons in the calipers themselves. if you had giant 6 pots (extreme example) youd need a bigger master to shift more fluid

Thats why my box and 4 pots came off and got thrown in a box many years ago. Hopfully this time I can get them to work! (my caliper pistons had too much area!)

[Harvey]

Darren/Ben it was my original thought that my larger m/c needed to go on the front due to the 4 pots but I have since been advised that I'm wrong, that's why I have swapped them round. This does tally up as I had the balance bar wound all the way to the front due to the rears locking up. I'll work out the surface area of my 4 pots and the original ATE calipers and post up my findings.

Update:
I've found out that my Hi Spec Billet 4 use a 24mm piston (4 pistons per caliper) so each caliper has a total piston surface area of 1810mm meaning the pair are 3620mm.
The standard ATE caliper uses a single 52mm diameter piston which has a surface area of 2124mm meaning the pair are 4248mm.

As you can see above the Hi Spec Billet 4 caliper are just less than the surface area of the standard ATE calipers.

This is just my brain dump so feel free to comment; Now for the bit I still struggle with in my head. If I needed to move more fluid I would think I need a larger bore m/c, correct for hydraulic clutches where you want a m/c to move the slave cylinder as far as possible to release a clutch fork but not for brakes. I believe it's the other way round for brakes so if you running a larger bore m/c you are moving more fluid so you get a harder pedal, less travel and require more force on the pedal where a smaller m/c offers softer pedal, more travel and less force pressing the pedal. I'm sure there are much better technical explanations for this but I can't be bothered searching round for them.

[BenH]

You have to double the the area for sliding calipers, as it's counted as a 'twin pot' so to speak. So you can call that 8496mm2. Trouble I had among other was my 4 pots were far to big, in comparison to the rears. To get the correct pressure, I ran out of travel.

Bottom right of top page. If your 4 pots were double what you have as standard, I know from experince you'd of had no front brakes to speak of. Mine were somthing like a 3rd to a half bigger :thumbsdown1:
http://www.rallydesign.co.uk/pdf/designing_4_pot_brakes.pdf

Edit. Are the gte pisiton's not 50mm diameter, looking at my notes? or is there a difference with 8v (late type) and 16v ones. My 4 pots were 43mm pistons!

[easytrans]

This is just my brain dump so feel free to comment; Now for the bit I still struggle with in my head. If I needed to move more fluid I would think I need a larger bore m/c, correct for hydraulic clutches where you want a m/c to move the slave cylinder as far as possible to release a clutch fork but not for brakes. I believe it's the other way round for brakes so if you running a larger bore m/c you are moving more fluid so you get a harder pedal, less travel and require more force on the pedal where a smaller m/c offers softer pedal, more travel and less force pressing the pedal. I'm sure there are much better technical explanations for this but I can't be bothered searching round for them.

Just thinking (not in anyway detailed technically), With a calliper in normal use the piston pots (calliper chambers) are fully charged with fluid and all the way back to the m/c so the extra "fluid" required to move the piston[s] (that usually sit a few thou from the disk) is minimal ....... Assuming the pistons are not driven back away from the disk (which I suspect could be the case in extreme rally surface driving) then the diameter of the master cylinder (m/c) would be less important for delivering the quantity of fluid but rather the "amount of travel / pressure" required to deliver it with the required force (pressure). .....

So am I right that: a smaller bore m/c (assuming the same travel) would provide slightly less fluid but under higher pressure than a larger bore m/c (assuming the same travel) but under less pressure.

If so my belief is:

small bore m/c same travel/same pedal pressure = less fluid higher pressure
large bore m/c same travel/same pedal pressure = more fluid lower pressure

The difference is probably so minimal that the main consideration is can the m/c provide enough fluid without resorting to a long travel to provide the extra (although small) amount of fluid to charge the larger area of all the calliper chambers under breaking?

I'll not get into expansion and fluid breakdown as it heats up or we will be here all day .....


Laurie.

[BlackBox]

If so my belief is:

small bore m/c same travel/same pedal pressure = less fluid higher pressure
large bore m/c same travel/same pedal pressure = more fluid lower pressure

The difference is probably so minimal that the main consideration is can the m/c provide enough fluid without resorting to a long travel to provide the extra (although small) amount of fluid to charge the larger area of all the calliper chambers under breaking?

I'll not get into expansion and fluid breakdown as it heats up or we will be here all day .....


Laurie.

Your theory sounds right to me

smaller bore m/c = more travel/less pedal pressure = more sensitive braking

I recently tried two different brake calipers, single pot sliding type. I forget exactly the piston dimeters but one was about 52mm and the other 55mm dia.
The difference in braking was phenomenal, the caliper larger piston was so sharp they scared me in a panic braking scenario and they were removed with the smaller ones being put back on.

[Harvey]

Ben - I didn't think about the sliding effect of the ATE caliper. Keeping this at a high level; A fixed caliper with two pistons at half the diameter of a single piston would offer the same braking efficiency as a single sliding caliper would it not?!?! This would mean that doubling the calculated piston area of a single sliding calipers setup isn't right. I suggest with your pedal box that you go for a .625 for the fronts and .750 for the rear to help balance out the braking to the fronts. You might also consider an in-line bias for the rear to bias even less to them. Might be worth speaking with some motorsport companies to ask what they use as some race cars run huge front calipers and must get round the issue that you had with you large front 4 pots.

Regarding ATE piston diameters the stock 256mm caliper has it stamped on the top of the caliper body 52/24 meaning it's a 52mm piston and a 24mm width disk. The 288mm and 308mm V6 caliper has 56/25 stamped on it meaning it uses a 56mm piston and a 25mm width disk. I believe the early GMF sliding caliper on the 1.8 GTE uses a 48/20 so 48mm piston and 20mm width disk, however the disk diameter was smaller and used a 236mm and not the 256mm as fitted to the later cars. I hope this info helps.

Laurie - I agree with your comments and your 'special' formula ;) as you have said I'm just discussing this at a high level so no requirement to go into huge detail, les keep this very basic.

[RallyMarshal]

The rallycar uses std 256mm ATE 16v calipers (albeit with motorsport pads) and has the std 16v rear discs fitted (albeit with shitty pads) and I do have the bias forwards but thats with moulded slicks that generate a lot of braking grip. I have a .625 front and a .7 rear fitted at the moment.

Paul..

[DarrenH]

Update:
I've found out that my Hi Spec Billet 4 use a 24mm piston (4 pistons per caliper) so each caliper has a total piston surface area of 1810mm meaning the pair are 3620mm.

The standard ATE caliper uses a single 52mm diameter piston which has a surface area of 2124mm meaning the pair are 4248mm.

ahh it never occured to me the 4 pots would be less (in total) so that makse sense they would need smaller master

[BenH]

Ben - I didn't think about the sliding effect of the ATE caliper. Keeping this at a high level; A fixed caliper with two pistons at half the diameter of a single piston would offer the same braking efficiency as a single sliding caliper would it not?!?! This would mean that doubling the calculated piston area of a single sliding calipers setup isn't right. I suggest with your pedal box that you go for a .625 for the fronts and .750 for the rear to help balance out the braking to the fronts. You might also consider an in-line bias for the rear to bias even less to them. Might be worth speaking with some motorsport companies to ask what they use as some race cars run huge front calipers and must get round the issue that you had with you large front 4 pots.

Regarding ATE piston diameters the stock 256mm caliper has it stamped on the top of the caliper body 52/24 meaning it's a 52mm piston and a 24mm width disk. The 288mm and 308mm V6 caliper has 56/25 stamped on it meaning it uses a 56mm piston and a 25mm width disk. I believe the early GMF sliding caliper on the 1.8 GTE uses a 48/20 so 48mm piston and 20mm width disk, however the disk diameter was smaller and used a 236mm and not the 256mm as fitted to the later cars. I hope this info helps.

Laurie - I agree with your comments and your 'special' formula ;) as you have said I'm just discussing this at a high level so no requirement to go into huge detail, les keep this very basic.

Yeah thats what I have fitted, .625 front and .75 rear. I'll see how it goes and I always have the .7 as a back up if I dont like the feel of it. As long as I can get it all working and feeling good I'll be happy. I have a bias valve somwhere, I dug it out and put it in a safe place. But that 'safe' place eludes me at the moment, I did put a break in the rear line to unscrew and fit it. If it's needed and can be found. Nice to meet you and Paul today as well :)


ahh it never occured to me the 4 pots would be less (in total) so that makse sense they would need smaller master

That and the fronts need a higher pressure compaired to the rears. There are so many other things as well that effect the feel, such a caliper efficiency and the leverage ratio. One day I'll get it right lol!

[DarrenH]

i assume this is also in isolation from any effort reducing valves to the rear, i.e there arent any ? (other than balance bar or aftermarket adjustable valve ?)

[Harvey]

As some may know the tiny 40amp SBD alternator I purchase the other year decided it didn’t want to output anything over 12v when the engine was running, not good when you need your battery charging. So out came my old faithful GM alternator which has been on since early last year. Luckily for me a mate of a mate was able to test the SBD alternator for me a few months ago and it was the stator and rotor that were deemed suspect. After realising SBD would want to charge me nearly £200 for a replacement I started researching and found some on eBay for around £100. The SBD alternator is actually a Nippon Denso unit exactly the same as this click me (http://www.rmlunits.com/Kubota_Various_Equipment__Plant_Agricultural__Alte rnator/100-086/). I bided my time and eventually got a cracking deal on two brand new 40amp units but these would need a bit of work, see below. My idea was to keep one of the 40amp units as a spare but I also recently got hold of a slightly larger 45amp alternator. As I plan on fitting Corsa B EPS (Electronic Power Steering) later this year I believe the 45amp unit will be a better option as the EPS will suck the juice a bit more.

Top is the faulty SBD, bottom left is the replacement 40amp and bottom right is the slightly larger 45amp unit.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1292697Small.jpg

Pulleys removed with help from my wheel nut impact gun and rubber oil filter wrench holding the pulley. New 40amp unit came with 62mm V pulley where the 45amp came with 70mm V. I use a 55mm 4vee.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1292695Small.jpg

Now the fun begins…

This is the rear of both 40amp units, as you can see the replacement alternator on the left has its battery terminal pointing upwards which would actually foul on my inlet manifold. This meant I had to spin the stator 90 degrees so the battery terminal would be the same as the SBD alternator on the right.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1292699Small.jpg

I started by removing the rear cover and the brushes.

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Then the voltage regulators were removed.

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The replacement alternator uses a voltage regulator that I thought used an Econoseal three pin plug but after purchasing one it was too small. After more reading I’ve found it’s a specific plug fitted to some Toyota’s and Japanese manufactured engines that use the Nippon Denso alternators. As yet I’ve not been able to source one but I’m working on it. New regulator on the left (brown) old regulator which uses a T plug on the right (black). Only two connections are required for the alternator to work on my GTE even though the new regulator has three. The extra pin on the new regulator is a permanent live sense wire which is not required. You only need an ignition live and the battery light connecting.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P1292710Small.jpg

Next up was to remove the rectifiers, these convert AC to DC. If you’re interested in reading up how alternators work http://en.wikipedia.org/wiki/Alternator]click ( [url) here[/url].

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[Harvey]

Then it was time to split the alternator case and remove the rotors.

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Rotors removed.

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I was now left with the stator to remove which are an interference fit. As the SBD alternator had a suspect stator I used it as a test removal before I went onto the new alternator.

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Suspect stator removed.

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It was now time to remove the new stator so I could spin it 90 degrees. Earlier this week I had purchased a set of pin punches so I used the 2.4mm punch and gently worked my around the body of the stator to gently ‘push’ it out. It took about 10 minutes to remove being careful not to damage or touch the windings.

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Before removal I had marked the outer stator body with a pencil, this meant I knew how far it needed to go back in and that I had it fitted correctly.

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Once the stator was in I refitted everything and used my original T connector regulator before attaching the 4vee pulley.

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Replacement alternator now with the battery terminal pointing upwards which is were I need it to be to fit it to the GTE.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2042747Small.jpg

I just need to wait for a warmer day without snow so I can fit it on the GTE and confirm it’s pumping out the correct voltage to charge the battery when the engine is running.

[BenH]

Looks good, did you fit a new brush pack? I always find the new ones take a good few minutes to bed in before giving out the correct voltage.

[DarrenH]

scary amount of intricate parts all over the place! and good work all round.

the denso alt looks allot like one in the celica.

there are companys that will refurb your old alternator, did you look down that route ?

[Harvey]

did you fit a new brush pack? I always find the new ones take a good few minutes to bed in before giving out the correct voltage.

Yes, brand new brushes fitted and thanks for the advice.



the denso alt looks allot like one in the celica.

there are companys that will refurb your old alternator, did you look down that route ?

The Nippon Denso alternators come as OE parts on a lot of the Jap stuff as well as compact tractors and plant engines! It was cheaper for me so source my own alternator then to get the faulty unit refurbed. I paid a fraction more for two brand new 40amp units than it would of been to get mine fixed. Now I know they are so easy to strip I'm going to look round for a replacement stator and rotor so I can get the SBD item refurbed myself and keep as a spare.

[Harvey]

As it was dry and surprisingly mild and warm this evening I popped my head torch on and cracked on swapping over the GTE alternators. It was too late to start the car and check the charging voltage so I’ll do that tomorrow when I get in from work.

OE alternator prior to removal

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2212708Medium.jpg

Big lad and ikle baby alternator

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Tiny but mighty Nippon Denso 40amp fitted

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2212713Medium.jpg

[BlackBox]

I like !!

Where did you get it from and that rose link? Is one thread left handed?

[BlackBox]

Ebay ... where else lol ...

[Harvey]

The fitting kit came direct from SBD around 2 years ago and yes the rose joint has one left and one right hand thread. You could buid your own kit quite easily but I just needed it at the time so purchased it complete. Once I've tested that it's charging OK this afternoon it's project Corsa B EPS so watch this space over the next few months...

[Harvey]

Tested the new Nippon Denso alternator this evening and all sorted.

Tested at just over 2,000rpm

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2222715Medium.jpg

With no load applied it’s looking healthy

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2222732Medium.jpg

With full load of headlights, interior lights, radiator fan and heater fans, not got many electrics left in the car apart from the bare minimum

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2222736Medium.jpg

Now at base idle of around 950rpm

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2222737Medium.jpg

My tiny battery is still doing its job very well

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P2222727Medium.jpg

All in all jobs a good’un with nice new shiny alternator doing what it should be.

[BlackBox]

Looks good there Harvey ....

[Harvey]

I was doing a full spanner check the other weekend on the GTE in preparation for a track day I have booked on Easter Monday. Glad I did as the first bolt I checked was a little unwell. The rear n/s lower shocked bolt required nipping up but the captive nut decided it wasn’t going to play anymore. At this point I had two options; remove rear beam and get a new M10 fine thread captive nut fitted or drill it through and replace with longer bolt and nut.

I chose the easier option, After a dig round in my shed I found a couple of longed M10 bolts used for rear engine mount on a Calibra Turbo.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P3250394Small.jpg

A plan was hatched to use an old shocked top washer to help spread the load when tight

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P3250398Small.jpg

What the origin bolt looks like.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P3250400Small.jpg

After both had been drilled through and replaced they looked like this.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P3250401Small.jpg

You can see the spacers either side of the spherical bearing on the lower mount for the GAS rear coilover. GAS supplied these but only after I asked for them.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P3250402Small.jpg

After my conscious got the better of me I decided an 8.8 tensile bolt wasn’t going to cut it as the original was a 10.9. As I now run coilovers and the rear shocker and spring are one unit I decided a 12.9 tensile bolt would be best. A quick browse on eBay and I found exactly what I was after, M10x70mm in 12.9 tensile strength.

Original bolt and 12.9.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P3290421Small.jpg

8.8 left, 10.9 middle, 12.9 right.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P3290418Small.jpg

I decided a new shake proof washer would be a good idea as well as a nyloc nut, you can never be too safe.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P3290422Small.jpg

To get to the new nut you have to poke your spanner through the hole in the beam on the underside here. You can also see the extra beam strengthening the shocker lower mount has had due to the coilovers I have fitted.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P3290429Small.jpg

All sorted so I’m a happy chappy.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P3290424Small.jpg

[Harvey]

I went to Blyton Park (www.blytonpark.co.uk) yesterday (Easter Monday) with the GTE for a track day, weather was crap, track was wet and slippery but it was still a great day. Lessons learnt were I definitely need EPS as more steering input was required due to conditions and if you get cocky it’ll bite you…I only managed the one spin. I was finding that I had to be more progressive and balancing the throttle powering out of corners otherwise it would just under steer and the Quaife diff just span both wheels. I was running Toyo T1-R and they did perform very well in the wet.

Last time the car was out in Jan I felt the brakes were spongy and soft since swapping the m/c over the correct way round. So I lengthened the front m/c push rod and they felt so much better. I had to move the balance bar more to the rear as the fronts were locking up. I softened up the rear shockers for the afternoon sessions to get more rear grip which worked very well.

A friend also came and brought his Nova, build diary over on PNG here ( http://www.pngclub.com/forum/showthread.php?114446-Iain-s-K-reg-Luxe-(Again!)) I recommend you all have a read. He was a proper nutter out there and loved the track as it was his first time there.

Here’s some pics my mate Keif took, thanks dude they are awesome. More pics of mine here (http://s1055.photobucket.com/albums/s512/griffinphotography2012/Blyton%20Park%20April2012/Harvey/), Iain’s Nova here (http://s1055.photobucket.com/albums/s512/griffinphotography2012/Blyton%20Park%20April2012/Iain/) and a real good selection of other motors there here (http://s1055.photobucket.com/albums/s512/griffinphotography2012/Blyton%20Park%20April2012/).

http://i1055.photobucket.com/albums/s512/griffinphotography2012/Blyton%20Park%20April2012/Harvey/IMG_1552.jpg

http://i1055.photobucket.com/albums/s512/griffinphotography2012/Blyton%20Park%20April2012/Harvey/IMG_1643.jpg

http://i1055.photobucket.com/albums/s512/griffinphotography2012/Blyton%20Park%20April2012/Harvey/IMG_1441.jpg

http://i1055.photobucket.com/albums/s512/griffinphotography2012/Blyton%20Park%20April2012/Harvey/IMG_1443.jpg

http://i1055.photobucket.com/albums/s512/griffinphotography2012/Blyton%20Park%20April2012/Harvey/IMG_1367.jpg

http://i1055.photobucket.com/albums/s512/griffinphotography2012/Blyton%20Park%20April2012/Harvey/IMG_1230.jpg

http://i1055.photobucket.com/albums/s512/griffinphotography2012/Blyton%20Park%20April2012/Harvey/IMG_1379.jpg

http://i1055.photobucket.com/albums/s512/griffinphotography2012/Blyton%20Park%20April2012/Harvey/IMG_1198.jpg

http://i1055.photobucket.com/albums/s512/griffinphotography2012/Blyton%20Park%20April2012/Harvey/IMG_1228.jpg

http://i1055.photobucket.com/albums/s512/griffinphotography2012/Blyton%20Park%20April2012/Harvey/IMG_1194.jpg

http://i1055.photobucket.com/albums/s512/griffinphotography2012/Blyton%20Park%20April2012/Harvey/IMG_1067.jpg

http://i1055.photobucket.com/albums/s512/griffinphotography2012/Blyton%20Park%20April2012/Harvey/IMG_1428.jpg

[BenH]

Love the first pic! Have you got you bias bar set correct? You need it set so the piviot bar is a 90' to the masters when you press on the brakes, so which ever master has the longer travel under braking thats the one that needs to be longer.

[mark2]

Those wheels are just perfect mate, nice pics.

[Nova Ian]

Looks like a brilliant day despite the poor weather you got. You happy with how the astra performed then?

I've spoken to iain and the bug has bitten him bad, he's already looking at booking another trackday before Cadwell at the end of may!!

Nice to hear some good reports of the t1rs from both you and Iain aswell as there my wet tyre too! I'm just missing the diff lol although as you and Iain both said it still took some controlling even with one fitted.

So when do you think your next outing will be?

Ian

[Harvey]

Love the first pic! Have you got you bias bar set correct? You need it set so the piviot bar is a 90' to the masters when you press on the brakes, so which ever master has the longer travel under braking thats the one that needs to be longer.

The push rod was set too short for the front m/c after I initially swapped them over. It's now setup properly as the front m/c requires a slightly longer push rod. The front smaller bore m/c moves less fluid but requires more movement where the rear larger bore m/c moves more fluid but require less movement.

If you look under the section 'Balance Bar Adjusting' on the Willwood site here (http://www.wilwood.com/TechTip/TechPedalTip.aspx) you'll see what I'm rambling on about.



So when do you think your next outing will be?


Probably sometime in June as I'm hoping to get to Mallory for a blast round. You should really think about a diff, just awesome in the dry and I would imagine if I hadn't got one on Monday it would of been a proper mare.

[Harvey]

A friend of mine had a Corsa C they were breaking and I was offered the EPS (Electric Power Steering) for a decent price so I decided to go for it. Ideally I wanted the Corsa B setup as it’s a bit lighter but knowing the Corsa C column had only covered 50K and being able to remove the setup myself I went and grabbed it this morning.

The Corsa C setup uses a larger and stronger motor than the Corsa B setup so I’m hoping I don’t get any issues with it. I plan on running the column off the AK 16 impulse transducer that feeds the LCD dash speedo instead of fitting an adjustable controller. From what I have found out the Corsa B/C uses a 15 impulse feed for the auto adjustment of the column so if my idea doesn’t work I’ve purchased a manual controller anyway so I can fit it if I don’t like the feel of the column.

I’m hoping to have the column trial fitted soon so keep an eye on my diary. Off outside now to get my dash removed.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4140498Medium.jpg

[Belmont turbo]

cool i've been thinking about fitting ESP to mine for a while but want sure if it will fit behind the dash so ill deffo be watching don't forget pictures :)

[BazW]

I was planning on being there on Monday as a present from my girlfriend but couldn't do it as I can't tax the SRi...gutted

T1-R's are good in the wet around Blyton. That's what mine had on the front when I was there the other week and at one bit it was throwing it down and I didn't upset it once

[tahir868]

Looks awesome that!!

[Harvey]

Busy Sunday at Donington BTCC meant no further work on the EPAS so this evening I cracked on and removed my existing height adjustable column and dash.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4160497Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4160499Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4160501Medium.jpg

The Corsa C EPAS column length is 585mm and the original mk2 column measures 590mm so looks like it won’t be as bad to fit as I first thought. The only unknown bit at the moment is the motor clearance so I’ll have a play later in the week if it stays dry.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4160502Medium.jpg

[Harvey]

More work on the EPAS as I fitted the rubber donut. Due to the steering rack being mounted along the centre of the bulkhead/firewall I was unable to use the intermediate shaft and had to use the existing rubber donut.

I began with a round splined end measuring 16mm in diameter and had to file it down to match the original column fixing 14mm.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4190502Medium.jpg

Here you can see the flat fixing I had to make the EPAS column fit.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4190500Medium.jpg

After a bit of work with the Dremel and a file I ended up with two flats on the end of the EPAS column. This allowed me to fit the rubber donut as shown.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4190505Medium.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/on%20going/P4190506Medium.jpg

[Harvey]

As the weather has been so poor of late I’ve not had chance to do any further work on the EPAS. So to keep you all amused here’s some interesting links. Details of EPAS from NSK the company who developed it here (http://www.tortoiselogic.com/NSK/PDF%5Cepas.pdf) (may take a bit of time to load the PDF). NSK initially developed EPAS for MGF and then the Corsa B for the European market and the latest EPAS info can be found here (http://www.nskeurope.com/cps/rde/xchg/eu_en/hs.xsl/electric-power-steering.html).

Initially I'll try and run it off the existing speed signal from the digi dash transducer as this runs at 16 impulses. The Corsa B and C speed signal runs at 15 impulses so in theory it should work but until I try it I won't know. I do have a backup plan as I've purchased a 'box of tricks' that mimics the Corsa speed signal and offers adjustable sensitivity via a potentiometer. So as you can read I have all bases covered once I have the column installed.

[BlackBox]

I don't know anything about EPAS, I'm guessing Electronic Power Assisted Steering ......?

What happens when the fuse pops?


Edit, sorry, I see it's still has a mechanical link, the new one is plastic designed to deform under impact ... that's interesting ....

[Harvey]

I don't know anything about EPAS.

You will when I've fitted it as I'm going to do a write up for the members How2 section ;)