GTE valver fast road/track car project

[Harvey]

I had always wanted a valver and flew up to Glasgow as WeeKenny (user on this board) was selling one which was perfect as it was near standard. I set about taking all the modded parts off and putting it back to complete standard apart from the stainless back box and Koni adjustables with Eibachs which I found second hand for £150 . Had it rolling roaded at Courtenays in Sept 2004 on a stock engine and it made 162.9bhp so I was very pleased click me (http://www.courtenaysport.co.uk/index.php?act=viewDoc&docId=56).

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Pre%20strip/GTE18-07-0411Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Pre%20strip/GTE18-07-047Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Pre%20strip/GTE18-07-049Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Pre%20strip/P2120023Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Pre%20strip/P2120031Medium.jpg

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More pics here (http://photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Pre%20strip/).

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I then decided to fit a full Deflex poly bush kit over Christmas of 2004

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Pre%20strip/Deflexbushes2Medium.jpg

They sent the incorrect rear beam bushes as the one’s shown above are for a mk3 rear beam, after a quick call the proper one’s arrived and were promptly fitted.

It was due for its MOT in April this year but failed as the drivers side steering rack mounting had to much play. At this point I knew I had to remove the intake and servo to gain access to get it welded.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Bare%20shell/P8060058Medium.jpg http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Bare%20shell/PA090012Medium.jpg

I had previously bought a second hand but never fitted Roll Centre 6 point bolt in cage from a guy in Milton Keynes and had been storing this on my spare bedroom for nearly 6 months. An idea popped into my head…why don’t I just bare shell the GTE and have a properly sorted and while I was at it have the cage welded in place. That was in April and this is now…

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Bare%20shell/PA160014Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Bare%20shell/PA160011Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Bare%20shell/PA160015Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Bare%20shell/PA160010Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Bare%20shell/PA160009Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Bare%20shell/PA160007Medium.jpg

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More pics here (http://photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Bare%20shell/).

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It took me nearly 6 months to get to this stage as I have been doing it as and when I have the time. It’s now totally stripped to a bare rolling shell with every bit of wiring removed, plastic clip, trim panel and sound deadening.

My plan now it to turn it into a fast road/track car and enjoy it even more. I already have a full set of red silicon hoses and Cobra Imola 2 seats to go in but first need to get all the front end stitch welded and all the remaining rust removed and rotten holes plated. Hoping to get it back from the body shop in January so more build pics to follow so keep your eyes peeled for up dates, although they probably won’t be very frequent knowing me.

Thanks for looking

Harvey

[DarrenH]

great little project, quite a few of those pics bring back some memories (bulkhead rust, tar mat removal)

could i strongley advise that you dont use the front wishbone front bushes. they seem to be the same poor design as powerflex. the stainless sleeve binds inside the poly bush and then the whole sleeve twists away against the chassis stub, eating into it and periodically making the bolt come loose.

also for the bitumen sound deadening. i found that warming the surface with a plumbers blow lamp, then wiping with blue tissue roll removed the worst. the remains came up with a squirt of carb cleaner or cellulose thinners type stuff.

[Harvey]

I've already sorted the front wishbone bushes as I have milled out the rear face and put a washer in between the bush and stub, then applied plenty of copper grease.

Harvey

[Jon S]

lovin this little project. cant belive how tidy the exterior is

[DarrenH]

I've already sorted the front wishbone bushes as I have milled out the rear face and put a washer in between the bush and stub, then applied plenty of copper grease.

Harvey

good plan :) i did something along those lines though, but it wasnt enough. just ate into the washer instead of the chassis stub.

not trying to belittle you or take away what youve done, just speaking from 5 years experience, but if you take a long look at how a standard bush is made and works, youll see the poly design even with mods is still doomed to failure.

[braders]

loks good to me mate, youve certainly got your work cut out there mate. good luck and keep us posted with your progress.

[richie00boy]

Love reading threads like this, great work. Amazing how rotten the engine bay is though when the exterior is so mint!

[Harvey]

My aim is to try and keep the car looking stock from the out with a stock engine at present due to the cost of the body shop work, which I haven't been quoted for yet. Anyways here's the list of the work to be carried out at the body shop, I'm sure I've missed something off.

• Weld cage in place
• Weld rear strut brace between rear struts
• Repair o/s steering rack box section
• Repair firewall to chassis o/s and n/s
• Remove all window sealer from front, back & side windows
• Plate battery tray inner wing n/s
• Plate n/s front outer chassis
• Stitch weld complete front end firewall, chassis legs, strut tops etc
• Plate floor pan hols o/s
• Plate rear floor pan hole
• Plate rear n/s inner panel
• Plate rear o/s inner wing at rear
• New roof skin or plate with sheet and sealer + pan head rivets
• Check floor pan & repair as necessary
• Check chassis and underside for any further plating inc doors and tailgate
• Sort all rust/surface rust on interior and exterior
• Under seal/wax oil complete underside of car and chassis.
• Spray engine bay, inside car, rocker & cam belt cover, paint code E474, mask cage as I want this remaining in the flat black colour
• Spray front and rear strut brace same as cage flat black don’t know paint code
• Spray trim parts in flat black as per the cage colour; scuttle panel, bumper inserts, roof rails, grill, door & boot handles, mirror base plates, side skirts

[Harvey]

Thanx for the bush comments Odders, I know exactly what you mean and I will be keeping an eye on it when she eventually gets put back on the road.

[Harvey]

Some of the parts I have already got for when I get the car back + I have a brand new quick rack in my shed (2.5 turns lock to lock) as the PAS has already been fitted to the other halfs SRi.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/Pa210001Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/Pa210002Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/PA210004Medium.jpg

[DarrenH]

turbo chris hose set :) calibra/cav 16v ?

my last word on the bush subject (promise) standard bushes are still available new from vauxhall. and the fronts are actually firmer than poly bushes ! purely because they have a large barrell shape metal carcass within the rubber. i went back to standard front bushes, but everything else is poly (rear bush, anti roll bar, rear beam) and it transformed the handling.

kirk out.

[Harvey]

Odder's, your thought's have been taken on board...over and out. Yes the Turbo Chris hose set, the very last Cav/Cally one he had in + a pair of heater matrix hoses.

Pic taken this morning by my other half just before my mate picked the car up on his flatbed
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Bare%20shell/PA220001Medium.jpg

I've now got some drive space back for all our other motors!!!

[Anthony]

Excellent project mate. Looking forward to seeing and reading about this ones progress! :)

[tomstickland]

How many Astras do you have?
Anyway, re your question on bulkhead welding, here's my link: http://www.tomstickland.co.uk/astra/mods2/suspension/Welding/day2.htm

[weekenny]

Glad to see its taking shape mate :)

[Brett]

just read this for the first time. Excellent project here mate, loving it. Very similar to what Im doing and also at a very similar stage!! Great looking car from the outside, but the usual rust gremilns to be sorted.

I will add from my own personal experience of running a GTE trackday car, theres a seem running down the inner wing. Its best got to by removing the wheel. It runs to the rear of the hole for the steering arm to come through. Check this for rust - at least get a bit of stitching done here as my old GTE literally got pulled apart. I also noticed some stess on the plate that the rear wishbone mount is welded to, I need to inspect further but I can see some rust in that area coming through the footwells of your car.

All the best for the project mate!

p.s. just noticed every car in that pictrue above appears to be a vaux (dont know whats under the car covers though!!

[Kris]

Its a like a pic from a vaux add .

[Harvey]

The one under cover is my other halfs show car, Astra mk3. Soon to be 3.0 V6 but I need to get my GTE sorted first. We've only got 5 Vauxhalls at the moment, 3 of which are mk2 Astra's :)

Popping down to body shop this afternoon to see if they have started anything yet. Will take a look at the parts Brett mentioned and get them seen to.

[Harvey]

Been at the body shop for three weeks now and they still haven't started it, at least it's off my drive. Keep popping in and telling them I need it back for end of December to help spur them on with it.

I was advised that it would be best to replace both front foot wells so I've just got hold of a pair of Hadrian panels for them to play with. Will get some pics when they start chopping bits out.

As my GTE 16v had a sunroof, as do 99% of them, I had two options. Either plate the hole with a sheet of steel or get a replacement roof skin. I tried everywhere and couldn't find a skin, Vauxhall quoted me £280 + vat but the part is no longer available. I popped down my local scrappers (Albert Looms, Spondon) last week for some other parts and spotted a mk2 with no sunroof, an idea popped into my head and a plan was hatched after speaking with my body shop guys. So with help from my dad and a early start at 08:00 this morning I did this
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PB190009Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PB190011Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PB190012Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PB190013Medium.jpg

I now have a near mint roof skin to go on the GTE and it only cost me £10 :) As I felt guilty for chopping up a mk2 I closed all the doors afterwards and replaced the boot hatch, don't think anyone will notice the roof is missing now :D

I’ve also bough a spare pair of front lower wish bone bushes on the advice from Odders and a new header tank as the ABS is not going back on. Also got a screen washer bottle from scrappers and it’s cleaned up really well thanks to the dish washer, don’t tell my other half!
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PB190014Medium.jpg

More updates as and when they happen.

[Sipo]

Loveing that cheesy grin mate! 1st time ive taken a look at this thread, as everyone else has sai, its hard to get your head around it when a mk2 looks so mint on the outside but is shot to bits under the skin! Awesome project you have on the go dude, I love seeing people take a car back to a bare shell then rebuild it. I know I would get it stripped, then get no further! Fair play to you, really looking forward to seeing the progress :D

[Tom]

Was just going to say the same as Sipo there about the rust, your heart must of sunk when you found the bulkhead like that :(

Look forward to seeing it all sorted matey :)

[Brett]

Those petrol powered stone cutting saws really are the bizz with the correct blade in. Gander and I have been up at my old GTE cutting various bits off - untill the bloody saw packed in:D

Where are they going to weld the skin in? If they do the join under where the plastic strip that covers the clips for the roofrack runs then you could maybe replace the clips and hide it?

[Jon S]

good idea doing a roof transplant, that 2nd pic remnded me of ...
http://www.horrordvds.com/reviews/n-z/tcm-ld/tcm_shot9l.jpg

[Harvey]

The roof skin is joined along the roof gutters so the join is hidden under the roof rails. Thought about removing the rails completely but that would be going away from the OE outside look I'm hoping to achieve. The roof still had frost on it when I removed it!

[_Steven_]

The roof skin is easy to replace, theres not actually that many spot welds to clear, tricky bit is its brazed on each corner under the roof rails. The centre support can still be got from the dealers for about £6 as it's the same as the mk3 (which has 2).

I think i got the last roof skin in England (about £230) and this one below me and Meady went to Norway for as he wanted a new one..

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

[Harvey]

Thought it was about time I popped down to see how the GTE was doing as it had been over two weeks since my last visit, it made me smile when I get there…

Second hand none sunroof roof skin fitted
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC090010Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC090021Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC090009Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC090020Medium.jpg

Engine bay nearly there
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC090011Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC090012Medium.jpg

Bulk head strengthening
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC090013Medium.jpg

New Hadrian floor pans and cage plates fitted
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC090014Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC090018Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC090019Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC090017Medium.jpg

Couple of inner wing patches
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/Pc090016Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC090015Medium.jpg

[_Steven_]

Some nice work there.. :)

[Sipo]

Indeed, some good work on the go. Will be a top motor when you are done :)

[Brett]

re your PM Harvey, I replied then came to check the thread as you said it has been updated.

2nd pic from bottom is the join that needs stitching up, runs top to bottom about an inch to the rear of the hole in the inner wing for the steering arm to come through.

[GazJevs84]

some good work by the looks of it mate keep it up dude

[astrasteve23]

comin on nicely, cant wait to see this one finnished! that is some tidy welding.

[Belmont turbo]

looking good mate seems to be a lot of resorations going on at the moment can't wait to see them all when there done.
keep up the good work

[Harvey]

Popped down the body shop this afternoon to see how things were progressing as I was suppose to be picking it up tomorrow but this has slipped back a week.

First off thanks to Oddball for the basic seat mounting idea but as he didn’t patent it I’ve nicked it.

The drivers side floor mounts for the buckets all welded in place. These have had captive nuts welded in to enable me to bolt straight to the floor and keep the seat mount strong. The seat can now be mounted roughly 70mm lower than if I had mounted the seats on top of the existing OE Vauxhall mounts with the sliders removed, if you get my drift.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/Pc160001Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC160004Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC160003Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC160002Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC160005Medium.jpg

Boot full of all the trims and other items that are being painted in flat black, the rocker and belt cover are being done in white. Plus the fixed rear strut brace where it should be…in the rear…also being painted in flat black.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC160007Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC160009Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC160008Medium.jpg

In all her glory on the ramps at last.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC160010Medium.jpg

[astrasteve23]

nice work. i might nick that seat mounting idea aswell! lowers the centre of gravity a bit.

[astrayorkie]

like the rear bar was it just welded in place or was a plate put behind it fixed then welded?

[GazJevs84]

good to see it is making some good progress mate

[Harvey]

The rear bar was welded in place with no extra plates as my body shop man said it didn't need any and would be strong enough with out them. His welding is fantastic and there is no way the rear brace will ever twist. I wasn't going to bother with it as it just adds extra weigh but I thought I'd do it as a precaution. The rear brace is the same material as the cage as I got it from RollCentre who made the cage, only cost £20.

[Harvey]

Definitely not getting it back now until the new year but at least I’m getting everything done that I want doing including a few extra bits.

A couple of full car shots until I get up close and personal later
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC210012Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC210013Medium.jpg

Both seat mounts now fitted with captive nuts so I can bolt straight to the floor with the side mounts before fitting the seats
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC210008Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC210011Medium.jpg

Steering rack box section on drivers side now repaired and properly sorted so no more flexing and MOT failures from now on, it’s as solid as a rock
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC210010Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC210005Medium.jpg

Bulk head now fully strengthen and rot replaced with metal
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC210004Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC210003Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC210007Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC210001Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/PC210002Medium.jpg

The new box section in the centre of the bulk head was made from my old roof and doesn’t look like it’s going to flex anymore. I was advised by Brett to get the seam stitched that runs top to bottom both sides of the car about 2” behind where the steering arms come through so this is next on my welders list then it’s spray time and finally play time when I get to put it all back together…minus a few bits of interior trim, wires, sound deadening etc

[Harvey]

A friend of mine is breaking his Nova track project and a couple of weeks ago mentioned some harnesses he had which sparked my interest. All I knew is they were Safety Devices items which I thought was odd as they don’t make harnesses. After I said I’d have them last night I picked them up today and found out there are Schroth Profi II items with the Safety Devices logo. Demon Tweeks sell a single harness for £140 inc VAT and I got the pair for £150, they are as new so I’m well chuffed.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/PC270051Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/PC270059Medium.jpg

The 'not valid' bit is the FIA approval not when the belts self destruct
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/PC270058Medium.jpg

The Schroth belts have a feature called ASM but not all their belts have his
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/PC270068Medium.jpg

I’m hoping my welded rear strut brace won’t be to far back so I can attach the harness shoulder belts and yes I know these belts shouldn’t pass an MOT because they aren’t EU marked but we’ll see when the time comes.

I'm also going to get the optional crotch straps as they are only about £10 per side and this will make the harnesses a 5 point fixing.

[DarrenH]

nice harnesses, pretty sure the eye bolts will screw straight into the standard floor mount on the sill and rear seat mountings. the transmission tunnel youll have to weld plates and captive nuts. they look the same thread as mine (7/16 inch)

my belts arent kite marked either, but you may have read in the thread, they passed fine. tester said they look at operation and condition of belts, fixings and buckels, not labels.

[GazJevs84]

they look like a decent bargain then mate

[_SBD16v]

my belts arent kite marked either, but you may have read in the thread, they passed fine. tester said they look at operation and condition of belts, fixings and buckels, not labels.

same as my tester said if there good enought for the fia then there good enought for him as iirc neither my seats or harrnesses have kite marks but both are fia aproved lol

[Harvey]

Thanks for the comments guys, all computed and taken on board.

I know the eye bolt will screw into the OE belt mount in the outer sills as these are 7/16" but I'll have to buy a couple of stress plates for the tunnel and drill out the OE rear tunnel seat mounts to use as an anchor point. From Demon Tweeks; Schroth stress plate is £4.90 and Willans is only £0.80, both look to do exactly what I need.

Last night my keen eye (I know I’m very sad) noticed that David Walliams on Top Gear was using the harnesses I bought in the reasonably priced car, they must be good if they are used in that monster of a machine.

[Harvey]

Today I mostly been in the shed sorting out my quick rack…
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/PC310051Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/PC310062Medium.jpg

The Deflex rack mounts and rack damper unit that helps to stop steering wheel vibration
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/PC310059Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/PC310058Medium.jpg

I also got my 7/16” Willans stress plates and a couple of spare eye bolts from Demon Tweeks this afternoon
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/PC310068Medium.jpg

I’ve also ordered the Schroth single crotch straps for both sides of the car so I don’t think I’ll be going anywhere in a hurry once I’m all strapped in.

Popping down to the body shop next Tuesday to ask the guys to weld the stress plates to the car.

[Harvey]

All welding now complete including the eye bolt stress plates, spraying to commence next week. I’ve been told it will be ready for collection next Saturday 14th Jan so I’m keeping my finger crossed it will be.

Just received my new steering wheel I purchased from an auction that didn’t hit reserve, I mailed the chap direct and we struck a deal including P&P. I’m chuffed to bits as it’s exactly what I was after and it’s virtually brand new.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1070056Medium.jpg

I also placed my order for the polycarbonate windows yesterday from here www.plastics4performance.co.uk. I chose stock bond in rear and quarter windows with OEM style black screen borders and the front side pair complete with slider kit. I got free postage because I mentioned www.vxscc.co.uk as I’m a regional organiser and of course www.astra-mk2.com. I was told they have a two week lead time so hoping to get these quickly so I can get them fitted as soon as my GTE is back home.

[Orange Peel]

Top job Hervey. I re-read this thread from time to time to remind me of what can be done :)

Have to sort out popping over soon :)

[Harvey]

Finished building the quick rack yesterday afternoon but had a few problems getting the centre tube for the bellows on the rack as it was a bit tight over the n/s outer bellow tie wrap area, ended up grinding a bit off the rack then about half an hour later everything was complete

Completed quick rack with naked OE rack behind
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1080052Medium.jpg

Damper unit bolted in place
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1080058Medium.jpg

Deflex o/s mount
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1080060Medium.jpg

Deflex n/s mount plus moded OE end rubber
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1080062Medium.jpg

[GazJevs84]

good stuff mate how is the car coming along?

[Harvey]

All welding now complete and spraying begins this week for pickup this coming Saturday...I hope...fingers crossed...touch wood...etc etc

[GazJevs84]

nice one good luck

[Defiance]

Looking nice harvey

btw harvey, Many mk2's @ that scrappy ???

Nowt near me (lichfield/rugeley/cannock areas) :(

Ciao

Have Fun

Def

[Harvey]

Disappointment set in on Thursday when I got a call to say the GTE won’t be ready Saturday, oh well.

I have been a busy bee over the last couple of weeks and bought some stuff off eBay

Snap off adaptor, don’t know how long it will last with the extra weight from the quick rack but I’ll try it anyway
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1150053Medium.jpg

HT leads brand new and red!
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1150051Medium.jpg

After speaking with Brett he advised that he got his dash flocking kit from www.frost.co.uk so I promptly ordered myself enough to cover mine

Flocking kit plus extra flock and glue
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1150058Medium.jpg

Due to the GTE not being ready I popped to my local scrap yard and got hold of some useful kit as well as the usually bits and pieces I didn’t got down for

Steel 2ltr 8v sump now fully restored and painted in black Hammerite, I’m getting an oil return pipe welded just above the sump plug so the catch tank will drain back into the sump and thus saving time manually emptying it and getting messy
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1150060Medium.jpg

Catch tank courtesy of the Daewoo Nexia, it’s a PAS bottle if you hadn’t already guessed
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1150062Medium.jpg

Shroth crotch straps ahave also arrived
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1150052Medium.jpg

[GazJevs84]

looks like some good stuff there mate liking the pas fluid tank lol

[Tom]

Have you got any pics of how the seatbelt plates were welded in on the tunnel ?

[weekenny]

Hey mate, just a btw you get alot of condensate in the catch tank and you dont really want the watery oily crap going back to your sump, my advice is ditch it doesnt fill up too quickly.

[Harvey]

I'll take the advice on board Kenny.

Just ordered myself a propper battery box that will be located behind the passenger seat and a underdrive single v alloy pulley from Trevor at www.rscmotorsport.com will post pictures when they arrive.

[Harvey]

Popped down to the body shop at lunch time today and they were just sealing the seams before painting, hopefully getting it back tomorrow.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1200058Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1200055Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1200056Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1200057Medium.jpg

Thanks to my keen eyes scouring the for sale section and Kev Read for selling them I now have a set of TAS engine mounts coming my way.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/TASmountsMedium.jpg

[astrasteve23]

shite didnt see them! how much did you pay for them?

[Brett]

looks really good mate! Your at the exact same stage as me now, Im painting my car this weekend too:D I like the extra bracing on the bulkhead.

Glad you got the flocking kit, its really good stuff and so easy to do its unreal!

[GazJevs84]

looking good mate

[Harvey]

It’s not home just yet as it’s only just had its first few coats yesterday. Final rolling shell pickup will be next Saturday.

Per primer
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1210054Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1210055Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1210059Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1210060Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1210061Medium.jpg

Primer
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1210062Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1210063Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1210064Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1210065Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1210067Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1210069Medium.jpg

Paint
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1210082Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1210079Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1210080Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1210081Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1210087Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1210089Medium.jpg

[Kris]

I love white gte's ,but am i right in saying that this is going to be a track car if so im ashamed as i dont even put half the effort into my road cars.

[Harvey]

A track car but also used on the road.

[Kris]

A track car but also used on the road.

Ah ,still a masive effort and it looks like the pay off will be a fresh looking gte :)

[astrasteve23]

that looks brilliant. cant wait to see this one finnished! how much is the bill from the bodyshop?

[GazJevs84]

lovely finish mate looking better all the time

[weekenny]

Nice to see it comming along mate :)

A car I should never have sold :(

[Gteman]

That is feckin lovely

http://www.clicksmilies.com/s0105/liebe/love-smiley-075.gif

[Brett]

top job mate, looks so much better when its all one colour LOL!

I wish I had been able to afford a bodyshop to do mine:(

[Harvey]

If I had the time to learn I would of done the body work myself, welding and spraying are the only things I can't do so I didn't have the choice. Plus I got a lot of overtime last year so saved like mad to get the the shell properly sorted. Funds are running tight now so I just hope I can find the rest of the money to put it all back together. I'm hoping to have it sorted for end of April but as long as it's ready for PVS and/or Retro I'll be a happy man.

[Belmont turbo]

wow that looks a real good job has been done there.

i need to find a body shop like that to do mine one day lol

[Harvey]

Bit of a mad day yesterday. Up at 07:40, chip ice off the run about, drive round to mates, throw tools and GTE steering parts into his Monterey, drive down to body shop to find GTE still in pieces but complete, bolt all items back on car plus steering parts and a seat, drag car back home on fixed bar while I’m freezing my nipples off over compensating with the quick rack.

Anyway at least she’s now back home with all the parts painted. Body shop hasn’t under sealed it but I can’t complain as they have done more than I initially asked them to. I’ll have sealing the underside myself over the next month. Cage feet aren’t welded in as I had requested but its lucky anyway as I’m now thinking it would look better in white so will more than likely get it painted next year.

I have also got my TAS engine mounts, thanks to Kev Read, which just need a bit of a paint to tidy them up. An eBay steering wheel boss which is an eKtor item machined alloy so nice and light. The polycarbonate windows arrived on Friday and I can’t believe just how light they are.

Got a bloody cold at the moment so unfortunately feel crap so won’t be bolting anymore stuff back on until next Sat but at least I’ve got the car back.

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1280057Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1280060Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1280061Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1280069Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/body%20shop/P1280073Medium.jpg

[a4r8n]

nice job mate just spent about 1/2 hour reading the whole thread top work wish I had the space/time/money to rebuild a car

[Harvey]

Got my dad helping out now as he's currently Hammeriting my fuel tank, front anti roll bar and TAS mounts. Also droping round the front struts and wish bones then once they are done the rear beam. Saves me about two days work :)

[traffman]

i remember seeing that valver at weekennys house and back then i thought it was mint....looks fantastic now.

[Belmont turbo]

that looks so nice:cloud9: i wouldn't want to drive it lol it mite get dirty:applause:

[Harvey]

I have to keep telling myself it's not a show car, it's being built to be driven...

[DarrenH]

amazing pictures. something very satisfying about a bare shell respray.

[Brett]

bloody hell mate, serously impressive stuff there!!! must feel really good to have the car back, and to have some bits back on it!!!

any polycarb windows gen? Ideally - how many windows have you had made up, where and cost:D lmao!


something very satisfying about a bare shell respray.

I totallys agree there mate. Theres also something very scary about a bare shell respray Ive found... and thats putting it all back! LOL!!!

[DarrenH]

dunno about you, but the feel good factor knowing the shell is A1 would keep me going for years.

[James C]

Harvey just make sure you never come off the track once you get it there!! Super Glue ur slicks!

We'd never forgive you :)

[richie00boy]

dunno about you, but the feel good factor knowing the shell is A1 would keep me going for years.

Yes I feel the same way.

Loving the pics Harvey, good job there. I'm thinking all that kind of thing might well happen to mine one day.

Did you spray the plastics a dark colour or have they just been dyed or treated?

[Brett]

dunno about you, but the feel good factor knowing the shell is A1 would keep me going for years.

oh yeah for sure me too, I've never liked the idea of driving a 'patchwork quilt' which is what my last GTE would have been to me after I'd got it sorted out.

The other thing I'm finding doing a baresehll rebuild like this is how mcuh better I feel knowing that I have inspected every inch of the shell, I know there are no hidden gremlins, and whats more as I peice it back together, I'll know how everything went together, thats its been done properly and how it works..... I guess its the 'in detail' aspect of the bare shell rebuild. Dunno if you feel the same thing Harvey?

[Harvey]

Thanks for all the comments guys I really appreciate it as it helps spur me along. I already have a show car that's not seen the light of day for over a year now and won't be out this year either due to the GTE taking over my life.

When I started out on this project my first aim was to get a mint shell and work up from there and it's getting to that stage but not quite there yet as I'll be a lot happier after I've under sealed, work starts this weekend.

It's all in the detail Brett so when the bodywork is sorted I'll be a lot happier. As I'm building this myself everything will be to my standard so if it takes me twice as long at least I'll know it's done right, that's what hope anyway.

All the trim parts have been wafted over in a satin black but it's still a bit to shiny for my liking as I ideally wanted a matt black finish but I suppose they will do. Just makes them look a bit tidier as I'm going for a stock exterior look.

My polycarbonate windows came from here www.plastics4performance.co.uk and I opted for OE mount front sides with slider kit (mount inside the door frame like normal windows), OE bond in rear quarters windows with OE black outer edging (they also do the opening version), OE bond in rear window with OE black outer edging. All windows are clear but they also do grey tint in polycarb, total was £265 as I got free postage because I mentioned www.astra-mk2.com on the phone and said I would give them a plug. Stock plastic windows with no fancy black edging are a lot cheaper but I wanted polycarb for their inherent strength.

Been sourcing some bits today and off to my local rally spare shop tomorrow to buy a couple of sample studs for the stud conversion I’ll be running.

As I said I’m taking my time over the build so it’s done properly but setting target dates for myself. Tomorrow night front struts and wish bones to be removed.

[Harvey]

Bit of a mad one this evening…

…gobbled dinner down and then went out to attack the GTE…

Strut and wish bones removed for painting
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2010058Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2010059Medium.jpg

Wings removed to check what needs under sealing, tacked back on as I’m running out of room for everything
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2010057Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2010053Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2010054Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2010051Medium.jpg

The mod I have done to the rear of the front wish bone bush to stop it sticking to the chassis stub, it’s been dremeled and the stainless bush insert cut down as I insert a washer (same as used on the nut end of the bolt) between the bush and stub.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2010055Medium.jpg

Also got a sample wheel stub and nut from my local motorsport supplier www.roadrunnermotorsport.co.uk looks to be exactly what I’m after so going to buy the full set now. These are special one’s for Vauxhall’s as the F**d version have a shorter splined section.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2010065Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2010062Medium.jpg

[Harvey]

Removed hubs from struts today and measured up the studs properly. Tim at www.tjmotorsport.co.uk has done me a cracking deal on the studs and nuts but need to check if the studs can be made with threads all the way to the end where the spline starts as steelies won't fit on hubs without spacers otherwise.

Trial fitted polycarb windows but will need to bolt and bond them in as they won't flex enough to just bond on.

Also got new front/rear bearings and ball joints. Dropped front anti roll bar, TAS mounts, wish bones and struts round at my Dads for painting.

Ordered front screen (green tint), battery and various stickers from Vauxhall.

[Harvey]

Attacked the dash today as I knew I was going to have to chop it about to get it to fit with the cage installed as the front cage legs on the RollCentre cage go through the dash. Finally after about two hours it now goes in OK.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2050053Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2050056Medium.jpg
Just need to sort the flocking now but think I’m only going to do the top of the dash as it’s not worth messing with the rest. Also going to be moving the fuse box to the passenger side above the glove box area as there is plenty of room.

[Xedrah]

Looking great! Good luck!

[astrasteve23]

looking good. i picked up a cage and fibreglass bonnet for my GTE today, the cage needs box sections welded in like yours has, did you by a kit of did the bodyshop make them up?

[GazJevs84]

looking good mate

[weekenny]

Looking great mate :)

Could use some nice cams tho ;)

btw I've still to take the Quaife diff'd F20 out of the corsa let me know if your still interested.

[Dan Gliballs]

Bllody hell!!! :eek: :eek:

First time I've seen this thread,.......................AMAZING!!!! :)

En entire mortgage worth infact. Hope to GOD you never crash this :(

Are you the same Harvey I bought my MSD stickers off on VVOC BTW? :cool:

[Harvey]

That's right Dan, my Veccy ST200 is in hibenation due to this project and has already been stuck in my garage for 15 months. I'm building the GTE on my drive and it currenty lives under a car cover as I've not got the windows in yet.

Kenny, I'm still saving and the engine still needs a rebuild before it goes back in.

[Harvey]

Todays updates but no pictures as it got to dark to take any.

Stripped and cleaned the heater matrix assembly and installed it in the car. Put a bead of silicone under the heater motor before bolting it in place.

Fitted the coil as I tripped over it in the bloody shed.

Fitted the bonnet release and stand. Decided against bonnet pins as I want the exterior to look standard.

Spent the rest of the car cleaning the inside of the door skins and the inner skin as it had double sided tape all over it. Removed the door skin sound deadening with a bit of help from a scraper and a heat gun. This lot look most of the day but it's been worth it as they look 100% better and are now ready for a quick blast of paint on the inner skin as my body shop didn't do the doors.

Have ordered a navigators foot rest and a drivers clutch rest as well as the studs and nuts for the hubs from www.tjmotorsport.co.uk.

Drilled and tapped my Snap Off boss as it didn't fit a Sparco steering wheel but does now.

Wish bones, struts, TAS mounts, front arb and fuel tank are all now painted in black hammerite.

[Brett]

youve been busy too mate it seems!

Will the heater matrix work better if I strip and clean it?? does it make a mess when you take it apart? I was going to bin it but decided now that its not worth the extra hassle of sorting a light weight replacement!

[Harvey]

My heater matrix assembly was full of thick dust so I just fully stripped it down and cleaned/dustered everything. I did the same with the heater motor. I wasn't going to put the heaters back into the car but decided against this idea as I have been speaking with a number of people who stripped theirs out and they have had issues with the windows misting up while driving in the rain.

[Brett]

theres plenty of dust in mine so I'll give that a clean tonight, good thinking there matey!

Still makes me laugh how you and I's cars are at almost exactly the same stages!!

[Brett]

just seen the pictures of your dash on the page before Harvey, flock the whole thing and peel off the vinyl stuff mate and flock onto that or the flock will just peel of in the heat. Just make sure you catch all the little lugs to screw stuff into, they go flying when you rip off the vinyl!!

[norm61]

My heater matrix assembly was full of thick dust so I just fully stripped it down and cleaned/dustered everything. I did the same with the heater motor. I wasn't going to put the heaters back into the car but decided against this idea as I have been speaking with a number of people who stripped theirs out and they have had issues with the windows misting up while driving in the rain.
mine has no heater matrix, temp doesnt bother me really, just put my beenie on! but seeing where you are going when its cold/wet even with the window open is a nightmare! even tried puting a hot water bottle in the car to help!

it doesnt, makes it worse:hissyfit:

everytime i go to buy a new one something else breaks:duh:

[Harvey]

Got my studs and nuts from www.tjmotorsport.co.uk today but they came direct from the manufactures www.graystonengineering.com the picture also shows the sample studs I have. You can see the difference with the spline length, the short spline versions are for F**ds.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2140053Medium.jpg

Also finished spraying my boss in satin black (thanks dad) and bolted the Snap Off adaptor to my steering wheel and added the yellow centre marker.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2140054Medium.jpg

[Harvey]

My navigators foot rest and drivers clutch rest arrived yesterday, they still have their protective cover on at the moment but are polished alloy underneath.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2160064Medium.jpg

[Brett]

tasty!

are you putting any plating in the floor? Im going to put some chequer stuff in I think, the paint will only get mullered!

[CraigGreen]

Skateboard grip tape on the floor IMO

[Harvey]

Under sealed both front inner arches and lower cross member yesterday. Had to go into work today so didn't manage to get any pictures as it was dark by the time I finished last night. Will get some pictures next weekend as I'm hoping to get the underside as far back as the fuel tank under sealed and the poly carb windows installed.

[DarrenH]

loving the updates :)

thought i would stick these two pictures up, seeing as its topical, and because i found them in my box of bits a few minutes ago...

these are the 2 washers i used between the powerflex sleeve and the chassis stub. same as the fix you detailed on previous page.

http://www.oddball123.pwp.blueyonder.co.uk/carstuff/powerflex_ouch01.jpg

http://www.oddball123.pwp.blueyonder.co.uk/carstuff/powerflex_ouch02.jpg

the washers are actually from the other end of the wishbone pivot bolts. i had 2 spare from some old bottom arms. flattened them out in a hydraulic press. they are 3mm thick, and the powerflex bushes still ate through them and further into the chassis. :yuck: :yuck:

[Harvey]

Mmm...you got me pondering now...do I use the Deflex bushes or fit the OE one's I bought...

[DarrenH]

well you know how i feel. but if the bushes werent such a poor design i'd still use the poly ones.

side by side, standard brand new bushes are firmer than the powerflex. thats because the standard bush has a metal carcass with a thin layer of rubber of the top, powerflex is just all flexible bush.

performance i'd say you wouldnt tell the difference, i couldnt. well to be fair, the standard bushes felt better simply because they fitted and worked properely. compared to a powerflex that keeps see-sawing itself loose and letting the wishbone move about.

the only real benefit in mk2 astra case is the fact that poly bushes wont wear out or degrade from age or oil contamination.

[Brett]

Ive been following this, the Yellow Astra was equiped with poly bushes on the wishbones too.

I had considered doing the harvey mod up untill now, but in light of what 0dders says there, I'll order up some new wishbones from Autovaux. Will save me having to drill the ball joints out of these ones too.

[DarrenH]

garys was eating into the leg, remember it documented on the many threads about powerflex chassis munching. also this from tomsticklands site


With time I replaced all of the standard rubber suspension bushes with Powerflex poly bushes. These are made from a harder rubber and therefore flex less when drivng the car hard. All sound in theory. Unfortunately I was very unhappy with the handling with the front ones fitted. The car seemed to wibble around and follow all the surface camber changes. I spent ages looking for the cause. Things were complicated by the need for structural welding along the way. After the welding was complete then things still weren't right on the handling front. The car would stick to the road on corners as good as ever, but the steering feel just wasn't right. I was at the rolling road when I mentioned this to the tuners and they told me to make sure that the bushes were greased up with Copper slip. So I took the front suspension apart. I discovered that the poly bushes had been binding and machining away the chassis leg. I wasn't too happy about this, plus I'd heard other people say the same things. Anyway, I greased the bushes up and reassembled everything.

http://www.tomstickland.co.uk/astra/mods2/suspension/poly6.jpg

On the road the car was transformed back to the good old ways. It felt so much better. Sadly, however, the results detiorated over the next two weeks until it was as bad as before. At this time I spoke to rally experts Harry Hockley. They confirmed my suspicions and advised me to use standard bushes and just change them every year to keep them firm. Seems I wasn't wrong then


"yes we know all about that. Grime and grit from the road causes them to lock up and wear away the mounting points. Use std rubber bushes, they're much nicer".

[Brett]

I hadnt actually noticed any such wear on the chassis stub on the car actually, I'll inspect closer as Im going over later to play with it somemore!

[Harvey]

OE bushes it is, I'm now converted.

Anyone want to buy a set of modded Deflex front lower wishbone bushes cheap?

[Brett]

Harvey, I ordered complete front wishbones from AutoVaux yesterday, and they told me that includes bottom ball joints and the OE bush:D Bought them because the OE bush looks a mission to get in and it saves me drilling the old ball joints off:D

£46.41 each inc VAT, on 2 day delivery too.

[DarrenH]

not bad. bushes arent too much hassle with some spacers, large sockets and a good vice. removing the olds ones is the b-stard. pivot bolt is 9 times out of ten welded to the bush with rust.

[astrasteve23]

how much for the set of modded Deflex front lower wishbone bushes?

[DarrenH]

you can have my poweflex ones for free if you like. collection only though lol !

[astrasteve23]

collection only, that'll cost me £45! lol. you just wanna see my van again!

[Harvey]

I got a pair of OE bushes for £22 from my local dealer and ball joints were £14 for the pair from my local motor factors. My existing wishbones are in great shape and have just been refurbished with Hammerite by my dad. I have a bush install/removal tool so fitting won't be a problem. My old OE bushes came out a treat and weren't even rusted/seized and just popped straight out with the assistance from my tool. I'll be keeping hold of my Deflex bushes just in case I have a change of mind or need then for something else as my run about has a new clunk when launching over speed bumps at greater than intended velocity.

[Brett]

What sort of tool is that Harvey? sort of thing that would be useful for getting bushes out of rear beams? I tried getting the bush out of my rear beam the other day and it wont budge, the sleeve must have rusted to the beam!!

I'm off to get a blow torch to burn the rubber bush out, then the sleeve might come out easier.

[Matt J]

Just read the lot, top work mate, you've got loads more commitment than me!

I just ripped all the stuff out and hammerited the floor pan as there was no rust.

[Harvey]

Put another coat of bitumen on the front inner wings and front lower x-member, these now look great and will help to repel the rust monster. Don’t have any pictures as it always seems to be dark when I’ve finished.

Removed Deflex front wish bone bushes and installed the new OE bushes. You can see from the picture the bush pressing tool I used. The tool comes as part of the rear adjustable camber kit for a Vectra B and has come in handy on a number of occasions.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2240063Medium.jpg

Got my resistox stainless bolts and wheel nuts back from the platers yesterday and I think they look well sexy in black.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2240066Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2240069Medium.jpg

Exhaust wrap ready and waiting for the front manifold 2”x50’ rolls and I got the stainless ties from Screwfix which aren’t pictured. My Sparco pedal covers sneaked into the picture as well.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2240065Medium.jpg

My polycarbonate windows in all their pre fitted glory bought from www.plastics4performance.co.uk with classy OE black edging.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1130074Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1130073Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1130075Medium.jpg

[astrasteve23]

got a few nice bits and pieces there mate. what are you doing with the old poly bushes?

[Harvey]

Old poly bushes will be staying in my box of stuff just in case I need them, think they are only about £8 for the pair from www.deflex.co.uk.

[GazJevs84]

looks like some good stuff mate

[Harvey]

I was a little shocked due to the lack of communications form RSC but I received my alloy under drive v-pulley and stainless bolts. I am however still waiting for the battery box.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1180051Medium.jpg

Hoping to get some more under sealing done this evening so you can all think of me on my lying on my back under the GTE in the cold this evening.

[Ross_Mk2]

Look after yourself in this weather mate :D quick question what does exhaust wrap do?

[Harvey]

Info below taken from www.thermotec.com

Wrapping the headers maintains exhaust gas heat within the header. This translates into more exhaust flow due to maintaining exhaust temperatures as it flows out of the engine. By improving the scavenging of spent gases, the engine breathes more efficiently. This reduces contamination of gases, thus allowing the engine to develop more power.

[Brett]

I admire the attention to detail your putting into this mate, impressive. Keep the piccys coming especially when the polycarbs are in!

Glad your stuff from RSC came btw!

[astrasteve23]

how much was that pulley?

[Harvey]

£90 inc p&p from RSC but I didn't think it would arrive, see RSC thread in the general area. They are £125 from Courtenay/Regal plus p&p so me thinks I got a bargain and there are proven power gains which I need on my stock C20XE that's going back in.

[astrasteve23]

yeah i missed one the other day by a day! it was £50 inc. p&p! was gutted.

[DarrenH]

really nice solution that. saves the hassle of converting to multi-vee. standard diametre too i take it ? so basically just a replica of the larger standard pulley, in alloy.

[Harvey]

It's and under drive pully and it's smaller than the OE alternator pulley diameter, it's more like the size of the PAS pulley.

My under drive alloy pulley is 125mm in diameter where the stock OE one is 150mm.

[Harvey]

Been busy this weekend as I planned on getting as much under sealing done as I could and getting the rear quarter windows and rear screen in. Spent Saturday afternoon under the GTE under sealing the sill’s and bull head back to the rear passenger foot wells. Sunday was spent fitting the rear screen and rear quarter windows. I must thank Andy Brown for all his help as the window fitting was not a one man job, just let me know when you want help refitting the rear diff of your Cav –T Andy. The front driver’s side window was trial fitted to see how it sat as I need some long bolts to hold it in position and to get the b-pillar stickers re-fitted before putting the window seal in place. All the poly carb windows still have their exterior protective film in place as I don’t want them getting scratched when I’m putting the cover on/off the car.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1210051Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1210052Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1210053Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1210054Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1220059Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1220061Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1220067Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1220074Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1220077Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1220082Medium.jpg

These are a few of the spare tyres I have for my OE 14” alloys plus there are five Astra mk3 Sport 15” steelies for track use when the GTE is ready.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1210055Medium.jpg

[Heathercdi]

looks like your making good progress there Harvey

[DarrenH]

what width are the steels ? i looked at some of the star shaped 15 inch astra sport steels and they were weird offset like et47 and only 5.5 inch wide. i was concerned about brake caliper clearance and passed on the offer. also steel isnt such a great heatsink, which might end up critical running track days with semi slicks on them.

just for the record, in my research i found a 4 stud, 6 inch wide, ET49 15 inch steel wheel in EPC but they were only used as spares in some of the early vectras !!!

what underseal did you use ? is it that hammerite with waxoil stuff ?

[Brett]

looks like I good weekends work there mate. Its when I see pics like that Im greatful mines already had a good undersealing underneath in the past!

Poly windows look really good mate, nice fit and the black marks improve the looks too. A step I'll take one day for sure!

[Harvey]

Odders your correct on all account regarding the steelies I have and they clear the Astra GTE 16v late spec ATE calipers no problem. I did know about the Veccy rims you mention but these Astra Sport steelies cost next to nothing and came with 5 decent tyres and centre caps.

This is the under seal I’m using and everything is getting a good two coats so it’s nice and thick.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1230052Medium.jpg

Picked up my freshly painted front arb from my dads this evening so that’s getting fitted tomorrow as I’m on holiday. It’ll also be more under sealing and sorting the fittings for the front door windows.

Ordered new all round brake discs and pads from my local dealer today, thank god for Trade Club or I’d be bankrupt by now.

[richworrall]

what ya messin about at mate, id have had this finished ages ago!!!! :D

how ya doin?

[Harvey]

Been on holiday today and even though it's been raining all day I have managed to get the front arb fitted and a second coat of under seal on. Didn't get the front windows sorted as it was to wet.

[mbjoyce]

did you get all new vinyl for the b pillars from your vaux dealer harvey?

[Harvey]

I have nearly got all the B and C pillar vinyl from my local dealer as I’m good friends with the parts guys and they have been really good and traced most of the parts I need. Some of the parts are the last ones available so I’ve been very lucky. I can confirm the boot vinyl for both early and late models is no longer serviced by Vauxhall or Opel.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1300053Medium.jpg

Got my hubs back from my mate Keif with the studs thread extended to the hub face and all fitted. He’s done a great job and saved me a lot of messing about. The rear hubs/discs have had the studs counter bored so they won’t foul the hand brake shoes.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1290062Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1290063Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1290064Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1290066Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1290067Medium.jpg

Managed to get the rear of the front hubs painted last night just before I went to bed as it would have been impossible to do once they were fitted. I did them in the kitchen and my other half never moaned at me, she’s just looking forward to driving the GTE once it’s built.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1290074Medium.jpg

Dropped the front struts off this morning at my local garage to have the front hubs and bearing pressed in and hoping to have the front end back on the ground and the rear beam removed by end of play today.

[pm3k]

looking good matey,too good to use on the track!!!!!!!!! why not get some mirrors and show it the bufty class!:wave: :wave:

[bigdrifter]

Way to nice a job for track use! Alot of very good work going on there

[Orange Peel]

Harvey - Could you find out if they still have or if they can get the black door piller vinal for the CDi? Mines OK but it wouldnt hurt to replace it.

[Harvey]

Work completed yesterday:

Front struts fitted as new bearings and hubs were pressed in by my local garage. Wish bones fitted and front end back on the ground. Rear end up in the air with rear beam removed. Pedals fitted to pedal box with Sparco pedal covers installed. Under sealing the rear half of the car on Wednesday evening and dropping the beam off at my dads so he can Hammerite it for me. I now feel things are progressing well but still have lots to do before Retro, just hope it’s all finished in time.

[Orange Peel]

Good luck mate. I really hope you get it sorted intim for the show's. If there's anything you need a hand with etc give me a shout.

PM replied too :)

[Harvey]

Tonight I mostly been stripping…….…my rear…….…beam. I have now dropped the beam and back plates at my dads for Hammeriting.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1310057Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P1310052Medium.jpg

[DarrenH]

showing us all up here harvey !! looking really good !

[Harvey]

I'm just not looking forward to the mini engine rebuild as this is something I haven't really done before. I'm renewing all the top end and bottom end gaskets and replacing the oil pump, water pump and cambelt+rollers and tensioner.

I'll be on my back tonight as I'm hoping to get the first coat of under seal on the rear half of the car.

[_SBD16v]

your screws that hold the windows in what are they made of they look black

[Harvey]

My window bolts are stainless steel. Originally they were a brushed stainless finish but I had them zinc plated in black along with my wheel nuts and Veccy ST200 wheel bolts. I didn't want them to stick out when fitted to the car, that's why I had them plated. You can't remove them front the outside of the car as they have shake proof washers and nyloc nuts on the inside, took two of use bloody ages to fit them all. I still need to tidy the window install as I'm going to put a bead of black silicone round the outside edge of the rear quarter windows and rear screen. If you need anymore info drop me a PM.

[Harvey]

It’s been a while since my last post but I’ve been a busy bee painting and cleaning things. The under side of the GTE is now fully under sealed with two full hand painted coats including the front and rear inner arches.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2160065Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2160068Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2160070Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2160071Medium.jpg

The rear beam is painted and ready for fitting this weekend. I have also made up some blanks for the ABS sensor holes. I have also over hauled the rear calipers and painted them.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2160077Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2160074Medium.jpg

I have cleaned my rear Koni shockers and they have come up really well. Just need to do the same on the rear springs.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2160075Medium.jpg

[Brett]

wow, that looks really good harvey, deffinatly help it last a few more years! I havent had the paitence to sit there and underseal the whole of my car yet, funnily enough yet again we're working n the same areas at the same time, Im working in the beam this weekend and planning to underseal the back like you have!

good to see its still coming along mate:D

[johnl]

Looks very impressive. Can't wait to see the finished item.

[Harvey]

Brett...that’s just spooky…

I bought a set of springs for my GTE over a year ago and have just dug them out. After comparing the rears to the Eibachs I was running they are 1" shorter but are a stiffer spring. I don't know what make the set is that I have but they are red with yellow print on the spring, possibly PI/Jamex/G-Max. I have now painted the rear pair and will try them instead of the Eibachs to see if it's any lower after refitting the rear beam.

Rear beam now have back plates, stub axles and hand brake shoes fitted and is ready to be mounted to the car. this will be done either later today or tomorrow, pics to follow.

[Harvey]

The difference in height of the Eibach and unknown rear springs.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2180057Medium.jpg

The rear beam still not fitted as I just didn’t get time today.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2180060Medium.jpg

Also picked up a pair of track rod ends yesterday as I’ve replaced the lower ball joints so thought I might as well do these.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2180062Medium.jpg

[Harvey]

Didn’t think I’d managed it as I’ve been busy doing other none car related things today……but finally the rear beam is now fitted. Got to fit the rear discs and hand brake cable and them she can be lower back to the ground. A big thanks to Andy for the helping hand once again.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2190053Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2190052Medium.jpg

Decided to try a little trick I have done to Amanda’s Astra mk3 and not run the rear damper pads, been using this on her car for over two years and it’s been fine. Use duck tape round the springs upper and lower pig tails. This method lowers the rear another 10mm or so.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2190058Medium.jpg

[alistair j]

thats not a bad idea that does it not wear the metal near the springs out tho harvey? looking veru clean under there by the way,.

[Harvey]

Not had any problems on the mk3 with the springs rubbing the metal away. The duck tape helps to stop this. As I said before it's been fitted on the mk3 for over two years with no problems and still passes the MOT.

[Harvey]

Managed to get the read hubs/discs fitted and the handbrake cable last night.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2200053Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2200067Medium.jpg

I also painted the lower rear valence and lower outer rear quarters as these tend to rot away so they might last a bit longer now.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2200052Medium.jpg

Here you can see the stud conversion I have fitted, only used two wheel nuts as the wheels will come off again when I’m sorting the brakes out.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2200056Medium.jpg

The rear n/s spring mount without damper pads installed.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2200065Medium.jpg

[Harvey]

Managed to t-cut and polish the rear bumper before fitting my freshly painted trims and finally putting it back on the car, all this got done last night and finished in the dark as usual. I'll get some pics this evening as I'm hoping to have a play with the front door windows before digging out the wiring at the weekend...full steam ahead in the vague hope it will be complete for Retro.

[Harvey]

The rear bumper with freshly painted inserts.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2230055Medium.jpg

I was replacing the track rod ends only to find that the near side one hadn’t been threaded all the way through and I don’t have and taps that big so going to swap it today for another one.

[Harvey]

Track rod ends and steering arms now fitted. Done a few small jobs on the GTE today and gave it a breather from sitting under the cover. Have now started work on lightening the loom and will post pics tomorrow. Got a set of decent wing bolts from the scrappers on my last visit and primed them today, top coat to follow tomorrow.

[_SBD16v]

if you still need a bottom pully pm me your addy and i will send you one on tuesday

[Harvey]

Attacked the looms over the weekend and fitted the light loom yesterday evening, will post pics this evening. Don't think I'll be moving the fuse box now as it'll be a pain to do and will involve a lot more work than I first thought.

So far stripped out the following looms/wires:
ABS
Radio and speaker
Headlight levers
Brake pad wear sensors
Heater rear window
Rear wiper
Trailer wiring

I'm keeping everything so I can weigh it when I'm done, not because I'm sad but for curiosity. I have also decided to keep the central locking as the car will need to be kept secure as I'll be using it on the road and the doors have been de-locked.

[Brett]

the loom side I really enjoyed! the amount of wires in the trailer socket is astonishing sint it LMFAO!

check control removal is where the real fun starts though:D

[DarrenH]

toms' spreadsheet says he removed 6kg of unused loom !!!

[Brett]

I weighed mine, along with all the relays, control boxes and units etc etc and it came to just under 10kg!!!

[Harvey]

Sunday fun in the living room while watching all the live action from the first round of the BTCC at Brands. It doesn’t look much but all this wiring is out of my GTE 16v, you can see I’ve stole Brett’s idea with the wiring loom plan laid out on the right of the picture.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2260051Medium.jpg

ABS loom in the foreground, scrap to the left light loom and main loom in the middle. My ABS is going on Amanda’s Astra mk3 when I get round to fitting the 3.0 V6 I have stashed away in my shed.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2260054Medium.jpg

ABS, c/l + e/h/m + e/w and scrap.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2260057Medium.jpg

Head light and tail light loom ready for refitting which got done on Sunday evening just before I lost the light.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2260058Medium.jpg

Wing bolts that got their final top coat in between rain showers on Sunday, let them to dry in the kitchen on the double radiator.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P2260072Medium.jpg

I have got the central locking loom completed this evening and removed the e/h/m and e/w wiring which formed about 75% of this loom. The bag of scrap is now getting heavy and I still have the mail car loom yet to attack.

[Brett]

looking very good mate!! the wiring diagram was steve heleys idea, he posted my one down to me. makes life so much easier.

Refitting it to the boot is loads of fun, trying to thread it down the rear sill withough damaging the flex.... be patient... LOL!

[Harvey]

I haven't used the wiring diagram yet as I know most of the wiring like the back of my hand in the Astra mk2, now that is really sad. Let's see if I can manage not looking at it for the main loom, I think not.

[Kris]

You put so much effort into all your cars Harvey you must have daily deliverys of Red Bull lol

[Harvey]

Since my last update I’ve been busy with the main car loom and chopping all the wires out I don’t need. I haven’t weighed it yet but I have a carrier bag full of wires but guess it’s at least 3kg.

Finally the looms are back in the car.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3070110Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3070113Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3070114Medium.jpg

A little blurry but I have just managed to fit the fuse box back where the cage goes through the dash, decided to keep it in it’s original location.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3070117Medium.jpg

I was talking with a friend and we came up with a thought. Due to the seats being as low as possible the steering rack would be sitting a little too high even though it’s adjustable. I then had a thought and mocked these spacers up yesterday and it’s works a treat and lowers the column perfectly without putting any extra stress on the rubber doughnut.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3070109Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3070107Medium.jpg

Lowering the column also helps with space through the dash.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3070118Medium.jpg

The dash also got it’s last trial fit yesterday before I flock the top half and get the screen fitted next weekend.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3070119Medium.jpg

[rhydgte]

Looks good mate :)

[Harvey]

I decided to properly seal the rear screen and side quarter windows from the outside with black silicon so popped to B&Q yesterday and spent a few hours getting very messy. I also dug the rear spoiler out on Friday and gave it a good t-cut and polish before fitting. To complete yesterday I aligned the boot hatch so it fits properly, it’s been bugging me for weeks but it’s sorted now.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3110158Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3110162Medium.jpg

[Harvey]

Cut down the GTE gear stick by 40mm yesterday and modified the lift up collar to take account of the shortened stick. Also managed to get the top of the dash flocked with the kit I bough from www.frost.co.uk, don’t know what it will look like yet as you have to leave it 24 hours to dry. Will get pics up later this week.

[Anthony]

Cut down the GTE gear stick by 40mm yesterday and modified the lift up collar to take account of the shortened stick. Also managed to get the top of the dash flocked with the kit I bough from www.frost.co.uk, don’t know what it will look like yet as you have to leave it 24 hours to dry. Will get pics up later this week.

Any pics of the flocked dash yet? :)
I've just bought mel's black dash so i'm tempted to do this before i fit it.

p.s. can't find it on that site :confused: what's it listed under please bud?

Regards
:)

[Harvey]

I’ve been busy doing other things this week so the dash is still hanging up in my shed, I'll get it down this evening and take some pics for you. I think it needs touching up in places but I can't properly see due to lack of light. Look here for the flocking kit http://www.frost.co.uk/item_Detail.asp?productID=9191 I have so far used half the glue and all the flock from the kit to do the sides and top of my dash. I also bought three extra bags of flock and an extra tub of glue. When I applied the glue I spread it with a small paint brush and simply sprayed the flock on. I used a big sheet and the extra flock that didn’t stick got swept up and reused.

[Anthony]

Nice one, cheers. Look forward to seeing what the dash comes out like mate, sounds good:applause:

[Harvey]

Looked at the flocking I did last weekend and it’s OK. It’s not 100% but it’s OK for my first attempt. At least it’ll stop the dash reflection in bright sunlight. I have also used foam filer in the side screen vents that sit under the speaker grills as they won’t function as intended as the grills aren’t going back in the car.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3170103Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3170105Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3170106Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3170107Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3170108Medium.jpg

Picked my new front screen up from Vauxhall today and hoping to get it fitted over the back holiday.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3170109Medium.jpg

Here’s my shortened gear stick. I could take another 10mm off if I really wanted but I think it’s short enough.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3170110Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3170111Medium.jpg

[richie00boy]

How much was the screen? I asked at my dealer and they said they just use Auto Windscreens or whatever.

[Brett]

the dash looks Ok Harvey!! perhaps more glue might give a more even finish, thats what my first attempt looked like too.

how much is a new screen then if you dont mind me asking? mine got a scratch in it where a wiper blade has been left unfixed in the past, Im hoping it might polish out at the moment!

[Harvey]

The screen cost me £70 but retails from Vauxhall is £102. I'm going to have another go at the dash and see if I can get it right this time round.

[Brett]

just use loads of glue and loads of flock, thats how I do it. I put down a clean peice of plastic to catch the excess flock and reuse it if I can.

Is £70 tradeclub? thats not bad really.

[rodg98133]

Looking Good

[Harvey]

Yes £70 for the screen is through trade club, I'm not a member but my local dealer always gives me the discount :)

Popped to the scrappers yesterday and got loads of bits and pieces, diesel mk2 rad (another spare one), ATE 256mm calipers and nearly new discs (loads of Veccy 288mm sets there), all the extra battery wiring due to me moving it behind the passenger seat, door looms for the central locking as I used my exiting in my run about, loads of screws clips grommets dash ducting door seals spare bulbs fuses stalks etc

Managed to get the front screen installed on Saturday and was planning on spending the morning on the car today but it’s raining.....I think its just stopped
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3180105Medium.jpg

This is the stuff I used to bond the front screen, I got it with my polycarb windows but used some different bond on them.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3180109Medium.jpg

[Brett]

more questions Harvey!

Diesel Mk2 Rad - is that bigger?? Theres a 1.6 Diesel MK2 festering on the farm where steve has his spare GTE thats all.....:D

[Harvey]

My OE rad is nadged and I spotted that the mk2 diesel had the same lower x-member as the 16v so I grabbed the rad as it looked brand new and only cost £10. I'll compare the two this evening and post some pics, they do look identical even though EPC lists different part number for them.

[Brett]

interesting!! Ive got 2 16v ones but I will probably have a look anyway, steve might want it you never know!

Cheers Havey!

[astrasteve23]

i have 2 spare 16v ones, one is brand new! no i wont sell one as it is very likely that i hit the front of the car on a rally. lol.

[Harvey]

Checked the mk2 17D radiators I have this evening and found that they are exactly the same as the C20XE, even the fan assembly is the same.

C20XE rad on the left with the two 17D rads I have. All the holes and mounts are exactly the same.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3210103Medium.jpg

C20XE fan assembly on the right. The 17D fans are again exactly the same but lighter as they are all plastic, the OE item won’t be getting fitted.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3210105Medium.jpg

Spent the evening tidying up the central locking wiring loom as I made a mistake and left three wires going to the n/s door which aren’t required. I have also moved the earth from the centre tunnel to where the control unit mounts. Going to get a Cav mk3 front n/s central locking motor as this contains the switch which activates the other motors when you push it down as well as a motor. The OE o/s central locking motor only contains the switch and doesn’t have a motor, that’s why you have to install a slave motor in the drives door if you want to run remote central locking.

[Brett]

I always thought you had to fit it to the passenger door Harvey? thats what I was going to do on mine unless Ive got it round the wrong way!

[richie00boy]

No, Harvey has it the right way. I had to get a slave motor in my drivers door when I had a Cat 1 system fitted.

[Harvey]

When the mk2 was built each door had a standard loom for both left and right hand drive.

For right hand drive the only central locking wires used in the n/s door are the black/red and black/yellow. These are either +ve or -ve so the motor pops up or down.

The only wires used in the o/s door are the brown (earth), brown/red and brown/white. These are used by the switch that feeds back to the central locking control unit which in turn applies the +ve or -ve to the black/red or black/yellow. The central locking unit in the o/s door only has the switch and doesn't have the motor.

I've now got a central locking motor/switch from a Cav mk3 boot as you can lock and unlock the central locking from the boot on a Cav. This unit has all five wires going to it as it contains both the switch and the motor.

[Brett]

arse, I didnt actually know what was involved at all then LMFAO!

I'll have to have a look and see whats going on with mine, IIRC I didnt touch the Central locking loom so it should still all bve there.

Cheers!

[Harvey]

I went through the whole car loom with a fine tooth comb and have properly removed everything I don't need.

[Brett]

yeah I did much the same as far as i trusted my electrical skills. And I still havent hooked it up to a battery yet! I avoided playing with lives where I could though.

[Efrain A.]

Brett, harvey...

the radiators are the same thing. the 17D radiatprs are the same used on the daewoo mk2 versions. (the ones i've had are the same as those)

but, the fans are not 100% the same.

on sartuday i picked up a plastic second hand fan assembly... i said "groovy this is lighter"... then i went to install it and the bloody thing hitted the standard XE manifold.

i had to do this:

http://upload4.postimage.org/188744/fan.jpg (http://upload4.postimage.org/cars/daewootech/188744/car.html)

and the assembly is still strong.

:Banane43:

[Brett]

I dont have the option of plastic fan on mine sadly, Ive got a turbo sitting there ready to do its own modifications to a plastic fan! ionteresting though. I owunder if the diesels have some sort of hybrid 16v/8v front!

[Harvey]

The diesel used the same front lower x-member and wish bones and I think some even had the same gear selector setup through the bulk head like the GTE 16v. It's amazing what you find out on EPC.

Thanks for the tip regarding the plastic fan assembly.

Managed to finish off the alarm wiring and I have now got the dash properly installed. Didn't finish until it was dark so I'll get some pictures tomorrow when I get in from work. Decided not to both re-flocking it as it'll do as it is.

[_SBD16v]

I dont have the option of plastic fan on mine sadly, Ive got a turbo sitting there ready to do its own modifications to a plastic fan! ionteresting though. I owunder if the diesels have some sort of hybrid 16v/8v front!


i have a plastic one in my astra ;)

[Harvey]

Yet another busy evening on the GTE as I won’t get anytime this weekend. Replaced the top o/s hinge pin as I had play in my existing, took a bit of persuasion to get the old one out but my patients paid off and I eventually managed it. Fitted the vent ducting and my suspicions came true as I have to mod the rear of the outer most side vents.

Here’s some pics of the dash finally fitted and bolted in place.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3240110Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3240112Medium.jpg

Also fitted the alloy spacers to help lower the steering column roughly 20mm. Keif who fitted the studs in my hubs machined these for me, cheers bud.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3240116Medium.jpg

Another point to note that some of you may be interested in is the black B pillar vinyl and boot vinyl. I made some enquiries at a local vinyl supplier as the OE stuff I have won’t fit properly due to me not using the original exterior rear quarter rubbers. www.thevinylcorporation.co.uk sell an exact match to the original vinyl called ‘blackboard vinyl’ and it’s sold by the meter with a max width of 610mm at £12+vat (£14.10). If anyone would like me to get them some and bring it to PVS/Retro/Billing drop me a PM as it’ll save you the postage cost.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3240120Medium.jpg

[Anthony]

The dash is looking swell mate!
Liking the vauxhall logo carpet in your lounge tho! :party:

[Brett]

I will take a roll of that at RC Harvey please! Unless your interested in parting with the OE side vinyls?

[_Steven_]

Any close up pics to see how close the match is? :)

[alistair j]

looking class still harvey, retro still the target?

[Harvey]

Don't think it'll be quite ready for Retro as I'm not cutting any corners to get if finish in a hurry. I'll get a close up of the vinyl later today and do a side by side comparison with the OE vinyl I have.

[_SBD16v]

if it fits well you can count me in :)

[Gteman]

I was going to mask mine not being able to find any in the right width. I'll be at retro hopefully with my astra, so I will check out the web sight cheers

[Harvey]

Here’s a picture of the OE door pillar vinyl on the left and the stuff I bough last week on the right. The OE vinyl is ever so slightly a smoother finish but I prefer the harder wearing vinyl I have bought. You could probably smooth the stuff I have down a little by t-cutting it once its been applied to the car. If anyone would like a small sample I’m sure the company I bought from will be able to supply one as this is what I did initially before I parted with any money.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3260115Medium.jpg

[Brett]

look like an excellent find harvey:D I'll deffo take some as per my PM!

cheers!

[Harvey]

If peeps want to replace all the black vinyl on their GTE you will need a 2m x 610mm sheet and this will be enough for the B and C pillars and the boot. The Boot panel measures 1170mm x 400m and this gives an extra 5mm at the ends to enable you to give a tidy wrap around on the side edges. Contact www.thevinylcorporation.co.uk and ask for the Blackboard Vinyl which is sold by the meter and comes in a max width of 610mm, they have it on 50m rolls so there is enough for everyone.

I’m going to be sorting out my B and C pillar vinyl this evening and will post pictures once I’ve complete it.

[Harvey]

Managed to get the B pillar door vinyl installed last night. As it is a really hard wearing vinyl you have to use a heat gun other wise you can’t bend it round the corners. Not going to get chance to finish it this evening but I’ll continue later in the week.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3280109Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P3280110Medium.jpg

[Brett]

:cool:

[CraigGreen]

Looks good Harvey.

Cant wait to see it on the tailgate........more bubbles than a sinking AERO !
(I tried fitting one to a Nova)

CG

[Harvey]

I'm cheating as I'm not doing the tailgate. The trick is to clean the surface with white spirits and let it dry, then heat the mounting surface with a heat gun, peel the backing off the vinyl sticker from one end and carefully apply by peeling the backing off bit by bit, hey presto no bubbles. If you also heat the vinyl gently it's very workable into corners and round bends.

[_SBD16v]

I'm cheating as I'm not doing the tailgate. The trick is to clean the surface with white spirits and let it dry, then heat the mounting surface with a heat gun, peel the backing off the vinyl sticker from one end and carefully apply by peeling the backing off bit by bit, hey presto no bubbles. If you also heat the vinyl gently it's very workable into corners and round bends.

not doing the tailgate
:hissyfit: :hissyfit: :hissyfit: :hissyfit:

[_Steven_]

Thanks for the sample Harvey!.. I think it's very close, infact, i'd say it was better than the genuine stuff.. Top find :)

[Ian T]

Agreed, that looks good.

Put me down for a metre of it please.

Cheers, Ian.

[rodg98133]

I must say this car is looking spot on. I saw it at Harvey's the other night and it looks great. Can't wait to see it finished.

[Harvey]

If you want just the sides doing 1m x 610mm is all you need @ £14.10 inc vat
If you want to do the sides and boot you will need 2m x 610mm @ "28.20 inc vat.

For anyone interested I can bring all the vinyl to PVS/Retro/Billing/Trax but it will need paying for in advance. Please drop me a PM and I'll send you payment details. If your not bothered about paying P&P (don't know the cost) then please contact www.thevinylcorporation.co.uk directly as I do not work for them. Can I also add I'm not making a penny out of this as the price listed on the www.thevinylcorporation.co.uk site is £12+vat per 1m x 610mm.

[Harvey]

Had a busy day yesterday as I was working on the GTE between the live BTCC races on MotorsTV. Finally managed to get the front side windows installed and the B pillar trims sorted. Still need to do the C pillar trims and was hoping to get them done this evening but the rain keeps on falling.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P4020126Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P4020129Medium.jpg

[Tony K]

Looks good sir. Much of a job to cut and match?

[Harvey]

You could say that Tony. Craft knife, heat gun, straigh edge and a steady hand and as my Dad always says 'measure twice, cut once'. I'm very pleased with the finished article and even more so now the front side windows are in.

[richworrall]

top work mate, you starting on mine when youve done yours? :Banane35:

[rodg98133]

Wont perspex windows be kinda unsecure if your using it as a road car aswel?

[Harvey]

They aren't perspex they are polycarbonate which is much stronger, only downside is they scratch easier then perspex. The windows I have are only as secure as glass, there won't be anything to nick out of the car as there's virtually nothing going back in. It can't be driven off as I'm fitting a Snap-Off boss and some trick immobilisers of my own design plus it's got a Cat2 immobiliser with coded key and a Lazerline alarm. If anyone wants to break into a car then there is no way of stopping them, most car crime is opportunist thieves. One thing I haven't worked out yet is how I'm going to secure the front side window sliders, possibly split pins or something like that, anyone got any ideas?

[weekenny]

http://homepage.ntlworld.com/kenny.greer/astra/Dscn0831.jpg

Cut down split pin on a chain with a wee hole in the runner to suit :)

[_SBD16v]

polycarb is 250 time stronger than glass

[Harvey]

Kenny have you got any closer pics as I'm not 100% sure what you mean?

Now that is strong Rob, lets hope I never need to break in!!!

[weekenny]

Kenny have you got any closer pics as I'm not 100% sure what you mean?


I'll go over to my dads and take some later in the week, if I forget PM me :)

[Harvey]

Not really done much due to the crap weather. Have now managed to get the c pillar vinyl in place and the rear quarter covers on. Also got a plastic marine battery box due to RSC not delivering the fiber glass one I ordered, will post pics later this evening. Popped to the scrappers…again…last weekend and got a few spares for the dash as I still need to cut and shut the dash side vents due to them fouling on the cage. I have decided to get a proper none servo assist twin m/s pedal box with in dash bias adjuster, just in the middle of researching this but Rally Design (http://www.rallydesign.co.uk) look favorite.

[Harvey]

Battery box to fit a 55amp battery, eBay special at £11.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P4130106Medium.jpg

[Brett]

Harvey, they are discussing doing a forum like this on MIG, so Ive mentioned the astra mk2 one as a good example and your thread here as an example of a diary, as I think its the best one on here. Hope you dont mind mate!

cheers for the item you sent me the other day btw, Will hopefully have time to play around with it at the weekend. Cheers Mate! beer for you at retro cars for that!

[Harvey]

No problem Brett, I enjoying keeping this updated...just wish the weather would make it's mind up what it's doing. Rob (SBD16V) PMed saying his 'item' works OK ;) hope you liked the install guide.

[weekenny]

Here's a close up of the 'locks' on my dads poly windows.

http://homepage.ntlworld.com/kenny.greer/astra/!cid_0Ll1KvO7MQ.jpg

http://homepage.ntlworld.com/kenny.greer/astra/!cid_dnclvXfsjd.jpg

[_SBD16v]

Here's a close up of the 'locks' on my dads poly windows.

http://homepage.ntlworld.com/kenny.greer/astra/!cid_0Ll1KvO7MQ.jpg

http://homepage.ntlworld.com/kenny.greer/astra/!cid_dnclvXfsjd.jpg


sorry but how does that stop someone opening the window

[Harvey]

Thanks Kenny but I was thinking the same. I'll have a head scratching session about mine and post once I have figured out what I'm doing.

[rodg98133]

I understand it...... I think!!!

[Harvey]

Been in contact with Tim at T J Motorsport (http://www.tjmotorsport.co.uk) and plans for a puka pedal box have began. We're both busy until near the end of June so I'll crack on with the heater ducking and how I'm going to secure the front window sliders. Also in the middle of breaking a Vectra B CDX and prepping our other cars for PVS this coming Sunday. Just don't know how I manage to fit work in between this lot!!!

[rodg98133]

wish I could come to this PVS but i'm at work

[Kris]

How would you rate the poly bush kit ?.What do you all get with the kit ?.

[dealersport]

dude, have just read your diary from begining to end, top work looking so good im just about to start my project i just hope it comes out some where close to the same quality as yours keep up the good work

[Belmont turbo]

how the progress going harvey

[Harvey]

Not touched the GTE this month I'm afraid to say as I've been way to busy working on our other cars and fitting holidays in as well. Hoping to contact Tim regarding the pedal box next week so things should start moving again once this has been purchased. Got a number of contacts now regarding the purchase of braided brake and fuel lines so should be able to work out rough prices as soon as I've measured the lengths. Finally got an equal length shaft which I've been meaning to purchase for ages, picked it up from PVS. Shame the GTE won't be ready for Retro but it will be next year, I’ll still be on the stand this year with Amanda’s SRi.

[Harvey]

Sorry Kris forgot about your question.

The Deflex poly bush kit is great value for money and it totally transformed the handling and road holding of my GTE 16v as I had the full kit fitted before the car was taken off the road. My car at the time also had Eibach springs and Koni adjustables so I was able to set the car up for exactly how I wanted it so the ride wasn't at all harsh or bouncy. I would expect if you have fixed rate shockers you may find the ride a little hard with poly bushes all round but I would still recommend you had them fitted as you'll never go back once you have tried them, worth every penny in my opinion.

[Harvey]

Finally I have an update because I’ve not touched the GTE this month, he says hanging head in shame. Been busy saving for the pedal box and braided hoses as well as working on our other cars.

Picked the fuel tank up from my dads as it was beginning to get in his way. All freshly painted in black Hammerite. Just need the braided brake hoses fitting before it can be put back on and also a new fuel level seal.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P6250006Medium.jpg
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P6250004Medium.jpg

Here’s a picture of the equal length shaft and short shaft I got from PVS minus the CV’s and boots which I’ll get brand new.
http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/rebuild/P6250009Medium.jpg

[Brett]

Harvey,

My car had braided hoses through its entire length when I got it, M/C to calliper, the pipes ran outside the car. I havent reused them because they werent long enough to run inside the car.

I remembered about them when I cleared the garage where I was keeping the car last night and dug them out, might they be any use to you?

[Harvey]

Possibly so Brett, I'll speak to you at Retro as I know the layout I want for the hoses.

[Brett]

Ok harvey, I can bring them along with me so you can have a look at them if you want?