Ian T's long term GTE project [Archive] - Page 2

Ian T

29-06-2006, 11:52 PM

Cheers Gaz. :)

Not much to add really, except that I've spent the last couple of evenings putting it all back together, and have driven it for work today, which all seemed to be fine, except for a small blow in the exhaust somewhere.

I've tidied up the bumper plastics a bit, refitted all of the interior, front bumper and inner arch liners with new expanding rivets. This evening I refitted the drivers side stone protection mouldings.

I've also built the RPM converter, but it's not fitted yet.

The pre-Retro job jist is now:

Replace fuel lines,
Refit NS stone protection mouldings,
Weld up exhaust blow,
Fit RPM converter behind instruments,
Fit new windscreen weather strip,
Refit steering wheel straight - I put it back on crooked after I had the dash out.

If I get time, then I'll fit the new rubber door strips, club stickers, cut back and polish the newly painted panels and clean the car inside and out - it's still covered in paint dust!

Ian.

micky taylor

29-06-2006, 11:56 PM

keep up the good work mate

Kris

29-06-2006, 11:57 PM

Not going to work then Ian

Ian T

30-06-2006, 12:03 AM

Not going to work then Ian

LOL... I wish - I've had to work all this week, which means I have between about 6 or 7pm and dark (currently 10pm) to get things done. Tomorrow I'm going to slope off early if I can and tackle some more. There's always Saturday morning!

Cheers Micky, hope you get up to the show mate, even if it is without your car. :(

Ian.

Ian T

30-06-2006, 11:10 PM

The pre-Retro job list is now:

Replace fuel lines, Done
Refit NS stone protection mouldings, Done
Weld up exhaust blow, Done temporary fix, needs replacing really
Fit RPM converter behind instruments, Done
Fit new windscreen weather strip, Maybe Saturday morning, or at the show
Refit steering wheel straight - I put it back on crooked after I had the dash out. Saturday morning

If I get time, then I'll fit the new rubber door strips, club stickers, cut back and polish the newly painted panels and clean the car inside and out - it's still covered in paint dust! No chance!

Progress added above...

Ian.

untouchable

01-07-2006, 06:12 PM

fantastic progress Ian...well done!!

Ian T

02-07-2006, 07:35 PM

Thanks Mel. :)

Nothing much to add, except that it made it up to Santa Pod and back without incident, made lots of fast noises in the tunnels on the M25 and was fairly civilised on the flatter bits.

I've got less stress now and can slow down again and take my time. The car is driveable and tidy enough to get around but if I'm keen enough I can polish the panels I've painted (some were just as they'd come out of the gun at the show :() and get on and paint the doors.

Another job I've got to do is learn about suspension - to understand what the right setting is for the Konis and see if I need new springs to increase the ride height a bit.

Happy though - I'll check over it this week to see if anything looks worse for wear after the trip, but it certainly seemed to be ok.

Great to see so many of you up there! :)

Ian.

Pete

02-07-2006, 09:04 PM

Wow, thats some project Ian! Don't know if i would have had the patience, my nova is testing it at the moment though! You did well with the filler, it can be very frustrating! Keep up the good work.....

Ian T

02-07-2006, 09:20 PM

Cheers Pete - feel free to offer a swap... I'll leave the engine in! Oh, and pay you the contents of my wallet and bank account!!!

Ian.

Harvey

02-07-2006, 09:56 PM

It was good to see it in the flesh Ian, I must say the Veccy intake system under a mk2 hood looks stunning. Can't wait to start Amanda's 3.0 V6conversion now...but wait...must finish GTE first...do'h!!!

Ian T

02-07-2006, 10:13 PM

I'll have to try and write a 'members only' Vectra V6 into a mk2 engine conversion how to guide, won't I? That is before I forget all the useful bits...

Mark will set me right, I'm sure!

Ian.

Gteman

02-07-2006, 11:22 PM

Great to see the car (and you) in the metal and flesh Ian.
You really have done a great job on your nameless car :grumpy: and have filled me with inspiration.

I will be there next year with Gertrude so you can poke and prod at my arches ;)

Kris

03-07-2006, 01:11 AM

It was looking very nice in the flesh Ian ,You wouldnt think it had just been put together a couple of days previous .A testoment to you i think.

Ian T

03-07-2006, 11:27 PM

That's very kind of you guys, being so close to it I only see the flaws. I'm going to sort the doors and then consider ripping the drivers side quarter back off and replacing that as a whole panel, to get a spot on arch shape.

Speaking to you guys at the show gave me some more encouragement too, kinda makes it all a little more worth while. :)

It'll never be a perfect car though!

Ian.

GazJevs84

05-07-2006, 01:59 AM

looks very nice in some of the retro pics mate possibly the best there due to all the work you have put in to it

i am gutted i have not seen it in the flesh as yet but there is always next year

cheers gaz

Ian T

05-07-2006, 06:54 PM

Thanks Gaz, it's nowhere near as nice as most of the other cars on the stand - the work is gradually making it rust free, but there were some seriously lovely cars there last weekend. The camera on this occasion is being very kind. :)

Ian.

cav

30-07-2006, 09:42 PM

Ive just been reading all this thread and all i can say is your a brave man doing all the work yourself, but it looks realy good pal

Ian T

30-07-2006, 09:56 PM

Thanks for your post, and welcome to the forums. :)

I've spent today on it as well, removed and stripped down both doors, drilled out the rivets holding the window mechanisms in, then removed all the glass, rubbers, lock barrels, lock mechanisms and CL stuff. Quite a thorough wash inside got rid of the 1990 vintage wax that was now flaking furiously and just dying to drop off. No wonder these cars go rusty! The doors are rust free, remarkably, seeing as they've never been treated, and the insides will be getting a good waxoyling before being refitted.

Then I rubbed down the area around the door locks to bare metal and cut two steel discs to fit inside the lock recesses, before welding them in.

Next job was to identify all the dings and marks in the paint, rub them back and apply filler to them, also at the same time filling over the lock holes. I don't have pictures today because I (as usual) forgot the camera!

So on with the plan:

The reason for removing the window mechanisms complete was to remove their arms and fit them onto Cavalier mechanisms, which have a bit more torque and also have the one touch function, which would be nice on the Astra, as well as convenience closure which would tie in very nicely with my deadlocks. ;)

What I need now are some standard door connectors to recover the pins out of, unless all of tem are already used in mine, as the cavalier window upgrade will need (3?) extra wires and the deadlocking needed one extra wire.

Hopefully I'll get back on the case during the week, as the rest of the prep on the doors is going to take a while. I've decided to have a go at the guide coat method to make sure I get the best finish I'm capable of getting. My spraywork is good enough for me, but it's always the prep that lets me down.

Ian.

Harvey

03-08-2006, 05:10 PM

You will find that there are spare holes available in your door loom plugs but no spare wires. I have spare connectors that can be popped into the door loom connectors but not sure how many. Might just have enough for 4 or 5 per side so I'll dig my bag out of spare wiring from my GTE and see what I have for you.

braders

03-08-2006, 06:01 PM

Looks great mate., A quick question for you did you paint the car with garage door wide open or closed? Just wondered how clean the paint finish came out.

Ian T

03-08-2006, 06:09 PM

A very good question.

Both times with the garage door open - mainly for light, but to be honest I didn't get much muck in the paint. The garage is in a pretty sheltered spot anyway, and the painting was mostly done on still days - the NSF wing was actually painted outside, on a trestle, on a lawn. That sounds like a big no no, but again the weather was very still and I only got one very small fly in the paint. Mostly it's not bits of grit that are the problem, it's the insects. Inside the garage doesen't seem to expose the paint to too many of them (none in the NSR quarter iirc) and I normally wet the floor a bit to keep flying dust down as best I can.

Ian.

Ian T

03-08-2006, 07:18 PM

Harvey

04-08-2006, 07:15 AM

Yes they do Ian, but I've been thinking you might be best grafting on a Veccy or similar door loom plug as they have a lot more connections. I'll check the mk2 connections this evening and cound them up as you might just get away with it.

Mark T

04-08-2006, 08:14 AM

Fit some DTM Style mirrors, then you've got 8 spare wires ;)

Ian T

10-09-2006, 11:02 AM

LOL... DTM mirrors look poo IMO.

Or just disconnect the mirrors - who needs them anyway? There's a slower time backup plan where I could use 3 wires to do everything and more in the door, but that uses a PIC so I'll leave it for now.

Been busy over the last couple of weeks, mainly prepping and spraying the doors. Not many photos really, must have been slacking again with the camera, but here are a few I did take:

Lock holes welded up and a skim of filler over the top.
http://img420.imageshack.us/img420/3310/gte779smallqi7.jpg

More prep done before primer, there's more to prepping a door than meets the eye, as there are MANY angles you'll be able to see it from after the paint, so it's not good enough just to spray the outside unless your colour match is very good - mine wasn't! This was a good chance to take out all the little dents and dings, the NS door was the worst for them and finished up the best in the end.
http://img420.imageshack.us/img420/2078/gte781smallkp5.jpg

After a couple of coats of primer and sanding with P800 netween coats, the colour coat and lacquer went on. Notice the lack of masking? Nothing to protect, as the doors were sprayed inside (door shuts) and out, so everything you can see when it is fitted is new paint. That's not to say it's a top job, of course.
http://img420.imageshack.us/img420/9986/gte787smallpl8.jpg

Next a bit of opportunity work, Mark T has already done this to his Mk2, but it took me back to when I owned my previous one back in 1992 (an '89F 1.3L), where I fitted mk2 Cavalier electric windows to it exactly by the same method. Take two GTE electric (or manual) window mechanisms and take two mk3 Cavalier electric front window mechanisms. Drill out the spot welds holding the Astra arms onto the driven gear and weld them in place of the Cavalier ones. Driving both mechs to the 'open' position allows you to match the angles, as it's the open position that matters, saves the window trying to exit the bottom of the door. The 'closed' position is managed by the frame, even as standard.

Window mechanisms - Cavalier ones at the top, Astra ones at the bottom:
http://img420.imageshack.us/img420/1688/gte783smallzz5.jpg

The front holes already match, but the rear ones aren't drilled on the Astra door, although if you look at most Astra mechanisms the frame extends to the same position and the holes do line up. Effectively, fit it at the front, then lay the opposite side mechanism over the door and mark the rear holes, drill and pop rivet into place. Easy.
http://img420.imageshack.us/img420/2339/gte796smallam4.jpg

Next the glass went back in, along with all the rubber strips, before the deadlock motor. The Cav motor has all the electronics in it for one touch operation, so needs 5 wires connected - two for power, two for up / down and one for the convenience closure function. To test it, I pushed the red power cable into the live side of a spare fuse position in the fuse box (yee-haw) and the brown into an unscrewed screw hole. That way I could get a look at whether it worked by connecting the brown/black convenience close wire to either the open or close wires. It's a massive improvement over the standard motors and well worth the effort. By comparison, the new mechanisms have lots of torque and move the windows up and down pretty effortlessly, the one touch function will be useful too. Total closure here we come.

And here's a picture with the drivers door refitted, finally a side that's all the same colour!
http://img420.imageshack.us/img420/6393/gte798smallgy5.jpg

The NS door is refitted onto the car now and I'll leave it to harden off fully (in the open position!) for a week or so before rebuilding it and attempting to cut the paint back. It'll be nice to have it back looking like a car again though. I guess the next thing will be to do all the wiring and then change the dash (when I find a Nexia heater box with AC).

Hopefully I'll get enough done to take it to Westerham next weekend, although I doubt the paint will be cut back and polished by then.

Ian.

astrachamp

10-09-2006, 11:11 AM

coming on nicely, silver ones do look nice :)

Ian T

10-09-2006, 11:22 AM

coming on nicely, silver ones do look nice :)

LOL - it's supposed to be Mistral Grey, although the paint I had made is rather lighter than it was supposed to be. Can't have everything I guess!

Ian.

Ian T

10-09-2006, 11:24 AM

Odd isn't it? The door still looks darker in the pic, but doesn't when you look at it. I guess it's possible it's different but it's all from the same batch of paint and I stirred it carefully each time I took some from the can.

Ian.

richie00boy

10-09-2006, 11:41 AM

Coming on well Ian, some nice mods making this into one of my favourite projects.

Think I will have to look into the Cav mech for mine.

bigdrifter

10-09-2006, 11:51 AM

Looking very good- gives me a good idea of how mine will look with the Turbo rims on. Have you got any rubbing issues with the tyres? I've got 195/50/16 tyres on and wondering whether or not to fit the Cav back axle or modify the GTE one because of arch clearance

Ian T

10-09-2006, 12:10 PM

I've got a mk3 Astra rear beam and no rubbing issues in the NSR arch, but when loaded I do get some rubbage in the OSR arch. Fronts are fine. T do have Cav size tyres fitted though, so I really ought to check that the rubbing only occurs with that size before doing anything about it - although it'll take years for me to wear that amount of tread off them!

Richie, it really is close to being a no brainer - the only downside to the Cav mechanisms is that you have to run the extra wires.

Thanks for the comments guys! :)

Ian.

Tony25

10-09-2006, 02:10 PM

Really looking good now, did you use 2k base and 1k clear??

bigdrifter

10-09-2006, 04:03 PM

Am I right to think that the mk3 Astra beam is the same width as a GTE 16v one and is the camber angle the same? My arch lips have been cut off already so this is about 3mm of lip at most but the arches are being replaced over winter so trying to work out whats going to work best

Ian T

10-09-2006, 04:55 PM

I used the Tetrosyl polyester colour and then Bodyline Ready for use lacquer - both are air dry products.

I'm not too knowledgeable about paints if I'm honest, I know I avoid the ones with the harmful isocyanates etc as I don't have the filtration system to deal with them.

---

Yep, the beam is the same dimension as the GTE one, but has the larger cutout for the rear ABS sensors that are integrated into the hubs of the Vectra stuff I'm using.

I've cut a bit back from the arch lips, although the only rubbing I get is at the top of the arch, not from the lip.

Ian.

bigdrifter

10-09-2006, 07:28 PM

Ah right- the 5 stud set-up I have is all Cav V6 (still on the donor car at the minute)

Ian T

10-09-2006, 07:52 PM

Yep, that's pretty much the same, either way it'll bolt up just fine.

Ian.

Matt N

10-09-2006, 08:04 PM

Looks amazing Ian, I hope I can get mine looking even half as good. I have upmost respect for you tackling it all yourself too, I'm not sure if I'd have the bottle!!!

I notice you saying about your Mistral Grey paint being quite a bit lighter than the original paint, my Cavalier was Mistral Grey and I found the genuine Vauxhall spray cans came out a LOT lighter. When I had a quote on the bodywork done the guy said he hates that colour because it is a complete bar steward to match.

Ian T

10-09-2006, 08:09 PM

Interesting - I just thought the paint was a duff match, or a duff mix, but Mark T uses the same company and has had reliable colour matching across several batches of his Mk4 colour, similar to diamond black.

A lot of it was DIY, but I have had a fair amount of help and motivation from Mark, especially in the engine department. I guess the thing for me was confidence in getting it right - I am happy that it can be done, that I can judge what's a good job and what's not, but when it comes to it I'd rather have some peer review going on. I know the bodywork side is my department and the mechanical side is more generally Mark's, but I'm enjoying it starting to come together now. There's still quite a lot to do, but it's got to the stage where I can do a bit, when I want, rather than have a massive list before the next MOT.

Ian.

Tony25

12-09-2006, 10:06 AM

Hi Ian I have just painted a door in silk violet using the same paints from brown brothers, base coat went on perfect, but found the lacquer went on with a very rough finish (overspray), Will probably cut back ok, just wondered how you got such a good even finish out the gun.

Ian T

12-09-2006, 10:24 AM

I know what you mean Tony.

Really, the way I got that was simply by putting a bit too much on. What I'd do is attack yours with a sanding block and P2400 paper (wet) to get it flatted back, leave a bit of orangepeeliness there for that OE look and then compound back with T Cut or G3. All I do is put the paint on with a dusty first coat over thw whole panel, before going over it straight away with the proper first coat. Then leave to flash off, paint again (proper coat) and leave to flash off again. While that's happening I pour the lacquer into a second gun and am ready to repeat the exact same process on that, with the exception that where you see some roughness you can quickly go over it with more lacquer and it will (not instantly) soften down to be a more orangepeely finish.

What you can't see in that pic is that I got a run above the top swage line. It'll sand out OK but it's still annoying! :)

Thanks for the comments though!

Ian T

12-09-2006, 10:42 AM

LOL... I've just realised, Tony, we use the same branch of Brown Brothers. ;)

I go there when I'm visiting Mark T. :)

Ian.

Tony25

12-09-2006, 10:46 AM

Just been out this morning, and flattened back some with some cutting compound, will be ok just needs more elbow grease :hissyfit:

Tony25

12-09-2006, 10:48 AM

Going back soon to stock up on some red in 2k, for my astra when it's ready for paint. Don't fancy spraying a mk2 in water. You not got a local brown brothers?

Ian T

12-09-2006, 10:54 AM

No local BB, there's a paint factors down at Brands Hatch, but I get good service from the Chelmsford place so I keep going back - Brands hatch isn't local to me either, and I don't much want to have to drive further into London to get paint.

The elbow grease method will work - only use the sanding block if you did originally when you flatted the primer back - otherwise you will end up with holes in the paint if there are high spots.

I used G3 polish for the first time last weekend and really rate it, really quick but doesn't give the impression it's taking loads of paint off. i'll see if I have any mishaps when I do the whole door though!

Ian.

Harvey

12-09-2006, 03:58 PM

Good progress being made Ian. I'll have to get my arse into gear and do something on my GTE as I've not touched it for a couple of months. Poked my head under the cover to check a loom plug and I've got to remove the dash and sort the main loom again as I've realised I left some wires in that I don't need.

Ian T

12-09-2006, 04:32 PM

Harvey, did you ever get chance to see if you'd got any spare loom connector terminals?

I'm currently working on the looms to re-use wires that aren't needed in the new configuration, but on the NS door, for example I have a choice of disconnecting the electric mirror (never used really) or running one extra wire with the loom. The latter sounds more probable at this stage.

Ian.

Harvey

13-09-2006, 09:36 AM

It keeps slipping my mind but I've just wrote it down so I'll take a look this evening for you as I definitely have some spare connectors.

Update - got you a selection of 4 pairs of wires. Two for the elec windows, thicker gauge and two c/l wires. PM me your address and I'll pop them in the post 1st class.

Ian T

14-09-2006, 07:27 PM

Thanks Harvey, PM inbound, you've just saved me my electric mirrors! :)

Cheers,

Ian.

Ian T

14-09-2006, 10:45 PM

OK, a small update, concerning wiring looms for the doors now that the deadlocks and Cavalier electric windows are fitted.

After a bit of consideration, I decided not to convert my electric mirrors into dumb ones, and to retain the (pretty crap looking) standard electric window switches. That means I need to run additiona wires through the door via the terminals that are coming from Harvey.

As standard, both doors are wired the same - global market stuff, you can swap the standard switch from the drivers door into the passenger door and the motor into the drivers door, and have LHD style locking - although that's pointless as a mod... ;) What that means to me is that there are two wires in the passenger door that aren't needed for the central locking, so I've stolen these to run the deadlocks and the convenience closure for the electric window.

The standard switch outputs the motor current in either polarity depending which way you press the button, so these two wires (yellow and blue) have been left as they are, but the ground input to the switch connected to 12V, so that 12V is switched onto either yellow or blue depending whether 'up' or 'down' is pressed. In the door loom these are connected to the 'open' (Blue/red) and 'close' (Grey/green) wires on the Cav motor.

The only pain really is in having to run a new permanent live into both doors - thinner wires are easier to poke into existing looms!

I think I've gone for the right option and hopefully tomorrow I'll fit the looms into the doors and make the 6 modifications to the car side of the loom to accept my new door looms. So I can get to Westerham in the Astra I'll run the wires outside the connector as a temporary measure until the terminals arrive.

So, for tomorrow night, I've got loads to do - Fit the NS Cav window mechanism, rubbers, glass and other bits, then the loom stuff, before I can put the door cards back and go out for a quick blast to remember what it sounds and goes like. Whatever doesn't get done tomorrow will have to happen Saturday, but it's looking like it will make it to Westerham, which is good.

Ian.

Ian T

16-09-2006, 06:36 PM

Hmmm... getting there.

A couple of pics, now that the nearside has been cut back and polished. As always, not a perfect job but will do for now. :)

http://img136.imageshack.us/img136/3131/gte805mediumcx8.jpg

http://img136.imageshack.us/img136/9384/gte816mediumdi7.jpg

I'm less happy with the drivers side for lots of reasons, one being that the door still looks like it's a slightly different colour to the rest of the car, I was able to see that by eye today as well, so it's not just the camera. ;)

So, as far as paint goes, I'd like to respray the whole of the drivers side, but still have the bumpers, mirrors, lower part of the tailgate and possibly the roof to do first.

It's un-rusty now anyway, which is good. :)

Ian.

bigdrifter

16-09-2006, 08:22 PM

Looking very good Ian

richie00boy

16-09-2006, 08:51 PM

Yes a job to be pleased with there.

Ian T

16-09-2006, 10:18 PM

Thanks guys, unfortunately I can't just go outside and have a look at it every 5 minutes, but tomorrow it'll get a wash and a trip to Westerham for the little meet.

I've got a small mound of wires that need to find homes and on account of the doors being missing while I prepped and sprayed them, and the car sitting outside, it's absolutely FULL of those little catkins seeds from the local silver birch trees it'll need a good clean out inside too - dunno how they always end up INSIDE the car!!!

Ian.

Sipo

17-09-2006, 10:32 AM

Fair play Ian, this has been a long haul but you are still sticking with it. A job being well done :thumbsup:

Dale

24-09-2006, 04:38 PM

looking good now mate

Mjl16vGTE

24-09-2006, 05:23 PM

cool stick with it!

GazJevs84

26-09-2006, 01:01 AM

looking really good mate :grinning-smiley-043

vauxmaster

03-10-2006, 05:22 PM

Superb project log Ian! :thumbsup:

Astra looks amazing! :cool:

BrightSpark

24-10-2006, 12:48 AM

looks spot on that ian :thumbsup:
wouldnt mind if mine was half as good as yours

Ian T

24-10-2006, 08:22 AM

Thanks for the comments guys, BrightSpark, it's honestly not asd good in real life, the camera is very kind. I've seen worse, but I've also seen better!

Ian.

twinturbo

20-02-2007, 08:55 PM

Seems to have come on quite a long way since I last saw it...

All good work :applause:

Not far of finshing my main project ;)

TT

banburygtecab

20-02-2007, 09:27 PM

if my comes out looking half as good i will be happy nice job fella

twinturbo

20-02-2007, 09:31 PM

Reading through all the post I saw mention of FxxxUEG was it ( 638 i can't remember exactly... ) And the window motor conversion... Takes me back a bit!!!

TT

Ian T

20-02-2007, 10:00 PM

Reading through all the post I saw mention of FxxxUEG was it ( 638 i can't remember exactly... ) And the window motor conversion... Takes me back a bit!!!

TT

Hi Rob,

Welcome to the forum... long time no hear!

I guess you'll remember being sat inside F638UEG on Bridlington sea front as I was preparing to exit through the sunroof... (?) ;)

There's a picture of the old White car on here somewhere, from her heyday. After I owned it, I believe it got attacked by the tippex monster and some loon colour coded the bumpers!

---

A chance for a few comments about car this thread is dedicated to... I've been driving it to and from work for the last few days (since Saturday morning) and actually could probably get used to it as an everyday car. I won't of course, as that means getting it dirty. ;)

It had sat in the garage since the Christmas meet, but oddly started up just as though I'd only used it earlier that day. Modern engine, I guess!

I'm sooo tempted to repaint it in white this year, or to look for another (white) shell and do a full job on that. I also think Mark T's suggestion was right about why it's party piece seems to be to spark up immediately on turning the key but immediately conking out. He suggested that the immobiliser wasn't getting time to authenticate, as I generally get in, turn the key straight round to III and start the engine. Since thinking about it and pausing before turning to III it's not done it once. This also fits with the symptom of only doing it from cold. So nothing to worry about - I expect with a normal weight flywheel it would carry on going long enough to catch up.

Happy days.

Hoping I can make the Westerham meet for more than a few minutes at the weekend, as I'm working too much at the moment and need to find some time out just st stay sane. ;)

Plans for this year are:

Relocate one rear brake pressure restrictor valve to below master cylinder
Source and fit taller (standard height) springs (AVOs fitted at present)
Make plate for Cavalier window switches in centre console
Replace steel brake lines
Replace steel fuel lines
Respray drivers side
Respray roof (maybe...!)
Respray tailgate bottom
Replace rear bumper with dethstar's one
Replace windscreen and weatherstrip
Replace drivers seat
Properly clean the interior
Clean engine bay and spray inner wing areas as needed

Parts wanted now:

Full carpet in beige, clean and with undamaged drivers heel pad.
Taller springs (closer to standard ride height, but for V6 weight)
Grey internal door handle surround

OK, so no progress, but a plan at least.

Ian.

micky taylor

20-02-2007, 11:21 PM

sounds like your going to be a busy boy mr t!!!

alistair j

20-02-2007, 11:44 PM

good going on this one ian. have a question for you, loking over yours and the vectra set up which you recon would make more power on my engine as i have been contemplating going for your vectra set up as i am concerned at the dents in the bonnet where th omegaset up keeps tring to get out.ha

just though as a quick question i would ask, as got chance of a set up same as yourself you recon it would loose power? sorry to gate crash the thread

Ian T

21-02-2007, 08:21 AM

Micky: Busy? yeah, I hope so, otherwise there's no point in keeping it! ;)

good going on this one ian. have a question for you, loking over yours and the vectra set up which you recon would make more power on my engine as i have been contemplating going for your vectra set up as i am concerned at the dents in the bonnet where th omegaset up keeps tring to get out.ha

just though as a quick question i would ask, as got chance of a set up same as yourself you recon it would loose power? sorry to gate crash the thread

Ally: I'm not sure to be honest, obviously you then have to change your engine loom and ECU - I think the Vectra setup will require that.

There are quite a lot of reasons NOT to change - for one you can get at your plugs without having it to bits and when you do want to take the inlet off, there are only a handful of bolts to undo. I've got 10 hose clips, several bolts etc.

Vectra setup looks prettier, Omega one just screams 3 Litres at me. :)

Ian.

twinturbo

21-02-2007, 09:46 AM

Yep I do remember sitting on Brid seafront with waves crashing over us, no life from the engien, DUD electric windows, blanked off door lockes ( no escape! ) and only the roof option to go for, and ... At least it proved the MOSS alarm could imobalise the car, and that panic wires should be protected from salt water ingress.....

Well your V6 conversion looks good, have you fitted teh equal length driveshafts yet? did it improve Torque steer to an acceptable level?

Here's where I am at rebuilding my car, been off the road longer than I had it on the road!

http://forum.fordsierraclub.co.uk/viewtopic.php?t=21185

Anyway, we holidaying in Kent this year so we must meet up for a day! Not sure if I will be brinnging the Sapphy down, most likly the Scorpio Cosworth as it's big enugh for all our crap...

TT

Ian T

21-02-2007, 09:50 PM

Hey Rob, that looks like a lot has happened to it since I saw it last. I remember taking you into some area of London to look at that, and having to leave my car keys with the people while we test drove it (they were scared of your driving perhaps?). Pretty remarkable that you've still got it even!

I dare say you remember the red one we looked at before that one? The impossibly clean and shiny one with lots of different colours, then the metallic blue one down some backstreet where the bloke blatantly didn't live... stood at the side of the road with the keys...

Ah well, happy days.

Ian.

twinturbo

22-02-2007, 09:51 AM

I remember leaving your car, and keys.... And my £1400 under the seat(shock) .

I remember almost buying the red 2.0 one, untill the woman said the V5 was still in the post.. Had to walk away.... I seem to remember most of it was resprayed and the door cards had been drawn on by the kids.

And the Metalik blue one... Yes, that drove realy well!! I stalled it twice, gave it to you and we Kangaroooood round the block... Easy to fix for me now, but a walk away at the time!

I have owned Erika for over 12 years! Many happy memories, many hours underneath welding too...

And I would never realy have bought a Sierra if it was not for you having your one...

Shame you have never kept any of your ealry cars, like the Samba ;)

Anyway, once the car's finsihed I will pop down for a visit ( seperate to the holiday ).

TT

twinturbo

22-02-2007, 09:58 AM

Do you remember that doddgy car warehous near dartford .. with the Sapphy right at the back being coverd in filler???

Anyway, bit of a thread hijack going on here....

The astra's looking good, I keep being tempted by MK1's and Monzas.. But I have to keep my focus on my Fords and VW's....

TT

Ian T

28-04-2007, 11:19 PM

LOL...

The good weather has returned and the Astra has been out of the garage for a month now, which means it's dirty.

Today's update is that I have moved the air filter into the OSF inner wing by fabricating a stainless steel joiner and using Cavalier C25XE inlet rubber pipework and a silicone pipe section so that the pipe to the air flow meter runs down through the punch out panel in the inner wing. The filter seems to fit there pretty well and now provides a source of cooler air to the engine, which has to be good news.

On my drive home from Mark's I've got to say it felt more responsive.

No pics today, but I'll get some at the RR meet tomorrow and we'll see how the old girl does on the rollers. Anything above 170bhp and 170lbft will be fine.

Ian.

mick g

29-04-2007, 12:44 AM

would your filter get covered in road shite poking into the front wheel arch?

Mark T

29-04-2007, 08:21 AM

would your filter get covered in road shite poking into the front wheel arch?

It'll get an arch liner before the weather turns.

I've got arch liners both sides on mine.

twinturbo

29-04-2007, 09:32 AM

Where they not standard?

TT

Ian T

29-04-2007, 08:28 PM

They were standard yes, but don't come down at the front, only the back.

RR day today, so here's the printout, for the record.

http://img66.imageshack.us/img66/8185/copyofrrmeet056mediumzc7.jpg

First time I've done one of these and I've got to say the guys at Engine Advantages handled the cars very well, and with lots of care.

Sadly that wasn't the case in the car park, when one of the group managed to chip my passenger door (the good one... :() by opening their door against it... twice! They'd gone by the time I found out, and there's no way they wouldn't have known they'd done it. I did think earlier on that for a 54 reg car the edges of the doors were very scuffed, now I know why.

So, I'm happy with the RR results, even though the operator suggested I might either have a problem with my airflow sensor or with the changeover valves swapping over too early on the inlet plenums.

I've noticed it not being as smooth as the Vectra V6 engine, so maybe there's something in that, and I'll have to investigate.

I also took snapshot runs with Tech2, so hopefully I'll be able to compare the results and see when I download it.

Ian.

twinturbo

06-07-2007, 10:05 PM

Front drains (sadly) are routed down the windscreen pillars and then vertically down into the sills through the A-pillars. The sad bit is that Vx never tried to make them exit the car, instead the pipe finished about 5mm above the lower line of the sill.

That'll be why they rust, then!

Sunroof drains are the same on the sierra, exiting in the sill.. Silly Idea.. I rerouted mine into the front arch area so they drain harmlesly away..

Easy to do I suspect on the astra with the bolt on pannels, not so easy on the sierra without welding..

I have pictures somwhere..

TT

Ian T

17-12-2007, 08:42 PM

I've just sat and re-read this whole thread and it's brought the memories flooding back. The amazing thing is that this was only started three years ago, as it seems to have been in one piece and road legal for most of the time I've owned it.

The only updates really are that it passed the MOT with no advisories this year and was complimented for its condition underneath. I've also given the engine an oil service and fitted an Ecotec oil pressure sender, so when I get some time I can wire that up to the GTE clocks.

I've got some jobs still to do, apart from the perennial urge to repaint it (making a better job) I still need to:

Fit the Mk3 GSi front springs
Replace all steel fuel lines with plastic ones (mk3)
Replace all steel brake lines with cupro-nickel ones
Relocate rear pressure reducing brake valves away from the master cylinder
Prepare and paint lower edge of tailgate

I'll update this with more as I think of it...

Ian.

twinturbo

17-12-2007, 09:22 PM

:applause: MOT :applause:

Hopefully we will be down for a visit some time in 1st Quater 08.. Last Time I saw it was after your wedding :)

I had my builder look at my garage plot, looking at 4mX7.5m . once that is built the Sapphy will be in for the final push!! Trying to avoid 8 years off the road!

Should have a result on the other project this Wednesday night. Schedule brought forward.

TT

Ian T

17-12-2007, 10:14 PM

Should have a result on the other project this Wednesday night. Schedule brought forward.

All the very best to you both on that one - we've reverted to Plan A as the baby is now head down and weighing about 6lb 3oz according to the latest scan. Due Boxing Day... But you knew that! :)

Ian.

GazJevs84

19-12-2007, 12:37 PM

All the very best to you both on that one - we've reverted to Plan A as the baby is now head down and weighing about 6lb 3oz according to the latest scan. Due Boxing Day... But you knew that! :)

Ian.

oooooooh what a time to have a baby lol

Time flies does'nt it my daughter is 13 months old now :fsfsfsfsf150: :fsfsfsfsf150:

JoeMK2

19-04-2008, 05:36 PM

aye great shell,how bad is the grey one?

Ian T

19-04-2008, 09:39 PM

aye great shell,how bad is the grey one?

I've moved these posts into this thread to keep them separate from the white GTE - hopefully it'll still make sense! You can read the reason why I've de V6'd this car here: http://www.astra-mk2.com/forum/showthread.php?t=18876

=======
LOL. The grey one is terrible, not rusty, the panels fit well, but unfortunately it's grey and I wanted white.

Made some more decisions today, as the grey one will probably go to someone I know, it'll keep its exhaust, which I've grown rather fond of. I'll have to look for another sometime. That means I've currently got no exhaust for the white one, so I'll have to get my thinking cap on and either duplicate the grey one's exhaust, or find something else. IIRC it's a Longlife Powerflow system, all stainless steel so it'll never rust.

Anyway, onto the progress. I've now got two Mk2 Astras that don't work. ;)

The XE came out yesterday and today it went into the grey one. Mark came down today and kept me motivated, not to mention grafting all day.

So, the photos...

V6 disconnected and ready to drop...
http://img227.imageshack.us/img227/8443/whitegte034oi7.jpg

V6 neatly stowed in the corner, waiting...
http://img89.imageshack.us/img89/7109/whitegte037smallym8.jpg

XE lying in wait...
http://img89.imageshack.us/img89/9549/whitegte032smallni7.jpg

Bay shot, showing the V6 engine mount, plus the drill marks where the original one was removed...
http://img216.imageshack.us/img216/9743/whitegte040small2iy4.jpg

New mount welded in, and XE is back in a car again...
http://img219.imageshack.us/img219/9575/whitegte043smallqf7.jpg

Underneath - I haven't cleaned it, but it's clean enough. No leaks from the rocker cover either, so it's obviously not too bad for an XE. ;)
http://img219.imageshack.us/img219/455/whitegte045smalloc5.jpg

And that'll do for today, I'm off for a bath!

Thanks go to Mark of course!

Ian.

jimbojetset

19-04-2008, 09:41 PM

Thats some progress top stuff

BazW

19-04-2008, 10:55 PM

Ian T

19-04-2008, 11:10 PM

i'll be on with de-LETing mine tomorrow :( made sure i didn't take it for one last blast either because i'll only end up changing my mind

what are you swapping over then? just the engine & box or the 5 stud set up too?

Just the engine and box at this stage. I had considered switching everything over, but I think the grey car is more saleable with the nice parts on it.

I did take mine out for one last drive this morning and got to the garage really struggling with the decision, so yes, I know how you will feel about it. I'm going to blame Mark if it's a bad decision, as I was stood there this morning looking at it wondering how I could take it to bits when it's the most sorted car I've ever had. He said, 'get on with it' or something similar and I think he's right, I've got a new project car now, this one.

Ian.

Mark T

20-04-2008, 07:47 PM

XE was all wired and running today.

Wiring is better than it was in the white one lol.

mick g

20-04-2008, 08:53 PM

You have been busy this weekend mate.

micky taylor

20-04-2008, 09:14 PM

XE was all wired and running today.

Wiring is better than it was in the white one lol.

yes i must agree it was a right lash job, done in a lunch time at work

Ian T

20-04-2008, 09:38 PM

yes i must agree it was a right lash job, done in a lunch time at work

LOL, it was functional. :)

You know what's odd? I've not even driven the white car yet, it's SORN at the end of the month and not insured, MOT runs out sometime next month and it'll be a little while before it's back on the road, might not make PVS, or (shock) even the Bromley Pageant.

Just got to get cracking on it now.

I'll fillet this thread later and transfer over the bits about the grey car into it's own diary thread, keep this one about the white one.

Mark's said it all really, today was a day of plumbing and welding, the original bottom crossmember went back in, although the bolt in one can still be refitted if required. The exhaust has gone back exactly as it was when I bought the car, to standard downpipes, standard centre section, then Powerflow 3rd section and back box.

Sounds better for some reason than it did with the original XE fitted, although the engine was rather tappy after fitting, no idea why, but hopefully there's no problem and it'll clear when it gets driven.

I've got tomorrow off work, but the nipper hasn't been well today so I think we'll be taking him to the doctors, otherwise I'd be back there to finish looming up the cables and tidying up the engine bay. Just needs doing really. I've also got to work out how to fit an ECU back into the factory position along with the Vectra central locking ECU, which had taken its place in the drivers side kick panel. I've also removed the Vectra diag connector and the rest of its engine loom.

Once the remaining wiring up is done, I need to rebuild the front end, and give it a proper test.

Thanks (again) to Mark for his time and enthusiasm. :)

Ian.