My 16v Project

[Dale]

Well i haven't been on the site for long but i have always loved astra's. My mate happened to have this Beast for sale, so i snapped it Up for a price of £1,200 with years M.O.T and 2 months tax Full vauxhall service history on 95,599miles. But as my bad luck goes i was driving my mates car which i thought i had 3rd part insurance on, got stopped by the police and i went to produce my doc's. turned out i didn't and i now have to go to court for driving without insurance. now this left me with a big problem. as i am only 18i can only get 6 points, i currently have a clean liecence but they said i will get 6 or more points, so in theory i won't be driving soon. so to keep my self busy i thought i'm not going tax the astra again i will rebuild it and turn it into the astra i have always wanted. I currently am a Learning techy (year 2) at BMW/MINI in Swindon, so i have the help of my work mates.

So far i have spent 2 days on it, as it isn't kept in a garage at my house. So far i have removed all the inside bar the dash and front sound proofing. i still have the engine to go and alot of the outside.

I am happy with what i have found so far being the car is 15years old. Inside i haven't found any holes yet (still have to remove the front sound proofing) i removed the side skirts today to find 3 holes in the seel which i expected. (See pictures below) When i removed the rear door cards i found rust flaking at the bottom.

So far i have found the car will be needing Rear Arches and both seels. But i won't start doing this till i have stripped all the car apart. i am also expecting the front inner wings to be a bit rusty but finger crossed they won't be!

With the astra i plan to put a 20LET in it, but i have alot on questions about that (depending on insurance quotes if i can do that) i am going to seem weld the whole engine bay or maybe even the car, get it re-sprayed and treated underneath so it will be ready for the LET even if i can't insure it. the other option is throttle bodies due to the insance of a LET. I am unsure about a Cage at this point in time and if i wanna keep the back stripped out. I will be getting a set of 16" Compomotive MO's with 4 pot 300mm hi spec front brakes. i plan to leave the rear's standard with tar ox discs and pads. Polly Bushes front and rear. These are my only plans at the moment but i am sure they will change as the project continues.

i already have koni adjustable Shocks with koni springs lower 40mm. so i don't want to change that.

Here are some pictures:

A couple before the strip started.

http://i40.photobucket.com/albums/e210/Scotchy11/Astra/P1030318.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/P1030319.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/P1030320.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/P1030321.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/P1030322.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/P1030323.jpg

Some pictures of what its looking like at the end of the day:

I really like it without the spoiler and i am tempted to get the holes filled.

http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0576.jpg

Whats left on the inside

http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0579.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0580.jpg

Hole 1

http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0581.jpg

Hole 2

http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0582.jpg

This is all i have done so far. will be posting some more pictures up next sunday.

Where does every buy there body panel from, the main dealer?

Cheers Dale

[untouchable]

Looks like a good project :D

[mking]

looks nice and tidy that mate, good luck :)

[Belmont turbo]

thats fooking nice mate and will be even nicer when youve finished

keep up the good work

[Dale]

where does every one get there body pannels from?

[Belmont turbo]

try these

http://www.beeversautopanels.co.uk/

http://www.sel-imperial.co.uk/

http://www.perfectpanels.co.uk/

http://www.bodyshopwarehouse.co.uk/

theres another place thats good but i can't remember the name begins with a H tho

[GazJevs84]

as above mate i am in the process of doing a resto too

http://www.astra-mk2.com/forum/showthread.php?t=9175

will be gettin my panels from beevers

looks like it is a good start and not too much rust is a good sign keep us upto date bud

oh btw i am gettin banned me thinks on 15 nov you can get 6-8 points for no insurance but 6 is the minimum so not looking good for ya at the moment ask your solicitor if you could claim hardship as you may lose your job if you lose your license cheers gaz.

[Dale]

as above mate i am in the process of doing a resto too

http://www.astra-mk2.com/forum/showthread.php?t=9175

will be gettin my panels from beevers

looks like it is a good start and not too much rust is a good sign keep us upto date bud

oh btw i am gettin banned me thinks on 15 nov you can get 6-8 points for no insurance but 6 is the minimum so not looking good for ya at the moment ask your solicitor if you could claim hardship as you may lose your job if you lose your license cheers gaz.

i have spoke to work and they have said i will keep my job so i am safe in that part. yer i got a solicitor, even if they do give me 6 points i can re-sit my liecence the same month because its not a ban they give me, just take my liecence away from me! which means i have to apply for a pervisional etc again. as i asked the police at the time of producing my documents

[Belmont turbo]

i have spoke to work and they have said i will keep my job so i am safe in that part. yer i got a solicitor, even if they do give me 6 points i can re-sit my liecence the same month because its not a ban they give me, just take my liecence away from me! which means i have to apply for a pervisional etc again. as i asked the police at the time of producing my documents


i had to do that afew month back :grumpy:

[GazJevs84]

i have spoke to work and they have said i will keep my job so i am safe in that part. yer i got a solicitor, even if they do give me 6 points i can re-sit my liecence the same month because its not a ban they give me, just take my liecence away from me! which means i have to apply for a pervisional etc again. as i asked the police at the time of producing my documents

ahh i see it is different if you have had your license over 2 years you dont have to do all that again but you have to serve the ban

i was just telling you just incase you did not know as my mate lost his job cos he lost his license and he was working at peugeot as an apprentice.

[Dale]

ahh i see it is different if you have had your license over 2 years you dont have to do all that again but you have to serve the ban

i was just telling you just incase you did not know as my mate lost his job cos he lost his license and he was working at peugeot as an apprentice.

ah ok, that was my first worry as i really like my job...... blah blah...... But was happy as soon as they said i would keept it :D

[GazJevs84]

sound bud :grinning-smiley-043

[DarrenH]

looks like a great base car for a project. normal nasties, but it looks clean.

if you do remove the spoiler (i'm kind of 50:50 on its looks too) you really need something there for functionality. the rear end gets very floaty at the high speeds cabable by the 16v.

the spoiler doesnt actually create downforce, it stops UPLIFT.

[Dale]

cheers for help so far will get some more pictures up on the wkend after another days work!

[Mjl16vGTE]

I dont mean to put dampners on things as the car looks really nice (better then mine!) but if you are 18 and now maybe 6 points you will never insure the GTE in a million years untill you are 21 most insurance companys will not touch you if your under 21 with a GTE. Thats why I had to wait till now to get one (21 now) So it could be a very long project! Expect qoutes of £3000 if you find one that will!!

[Dale]

I dont mean to put dampners on things as the car looks really nice (better then mine!) but if you are 18 and now maybe 6 points you will never insure the GTE in a million years untill you are 21 most insurance companys will not touch you if your under 21 with a GTE. Thats why I had to wait till now to get one (21 now) So it could be a very long project! Expect qoutes of £3000 if you find one that will!!

thats why i am taking my time to do it. i am 19 in december. so i have two years too build it! i wasn't going bring it out till i am 21 any ways.

[Mjl16vGTE]

Ok cool then that will be a wicked 21st present to yourself!!

[Dale]

Well been busy again today. only had one problem today tho and thats was getting the steering wheel off. tried everything pulling hitting, shocking the middle with punch and hammer just wouldn't come off. so in the end we just removed the whole colum.

took the wings off and as you can see in the pictures its only seems to be a bit of surface rust which i am pritty happy with and also the battery tray seems good from what i can see. after i removed the rear bumper and checked the rear of the arch's i was surprised to find them solid so at least thats one good bit of news! Still got alot of work to do tho.

any how cheers for the replys so far lads here's a couple more pictures:

http://i40.photobucket.com/albums/e210/Scotchy11/Astra/Picture007.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/Picture006.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/Picture005.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/Picture004.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/Picture003.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/Picture002.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/Picture001.jpg

On this picture above is the bottom black bar meant to be bent its seems to be the same both side??

cheers dale

[Kev Read]

They are suposed to be straight, but they are very weak and are usually bent on lowerd 16v's where they hit stuff like kerbs etc.

Good to see you have choose the legend that is the GTE as a car (or weapon!). A lot of blokes your age get chaved up saxo's etc.
Im sure you will enjoy owning and driving the astra GTE 16v. I have.

:grinning-smiley-043 :grinning-smiley-043 :grinning-smiley-043 :grinning-smiley-043

[bigdrifter]

Good work fella

[Dale]

Well i went to court last friday for the Driving without insure misshap! the out come was a 28day Ban, £235 fine and no points which i am really happy with.

[Dale]

did some more work on sunday, removed all the wires from the rear to the dash section, removed sunroof, headlining, driver door card and cleared the garage so i can put the mk2 in the middle to make it easier to remove the engine! here's a few pictures:


http://i40.photobucket.com/albums/e210/Scotchy11/Astra/Back.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/Side.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/Door.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/DriversFloorPan.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/RearFloorPan.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/Inside.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/Hmm.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/Sunroofout.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/RoofLining.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/Sleeping.jpg

Can't work on the car this weekend, but hoping to get the engine out for the weekend after! Then continue the strip so it can have the welding sorted and be sent for sand blasting and painting :), still not sure on a colour yet! been around work mate house sorting out what i want to get done! so should be alot more progress soon!

[Danny]

Good project you got there Dale.
It's always inspiring to see people taking on this level of work.

Another firm for panels is LMC Hadrian Ltd.
Their number is 01373 865 684.

Good luck on the project mate.

[Dale]

well another weekend gone and a couple more hours put into the astra! Me and my Friend mark wanted to get engine out this weekend and were unable to get a hold of an engine craine. so we decided to use a mini trolly jack + a peice of wood and hope for the best to remove the engine, box and shafts as one! it all went smoothly untill the trolly jack decided it wanted the start moving out when it had the engine on it, while me and mark were holding the engine, mark tried to stop it with his foot but it was having none of it, so in the end it just sliped off to say and bang it was out! well that was that done then!

I looked around the anti roll bars mounts and near lower arm for rust all looking ok! now just to check by steering rack when i remove the sound deading next weekend!

i also noticed that mine had the hole covered under the airbox is this standard on late GTE's or not?

At some time this car has had new brake pipes and well they were all over the place :(

Well Here's a few pictures:

http://i40.photobucket.com/albums/e210/Scotchy11/Astra/TheWagon.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/Workshop1.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/AirBoxHole.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/EngineWithoutRadandManifold1.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/EngineWithoutRadandManifold2.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/BrakePipes3.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/EngineDropped1.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/BrakePipes4.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/PullingEngineOut1.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/PullingEngineOut2.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/EngineOut2-1.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0736.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/BrakePipes5.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/Bulkhead.jpg

[Dale]

well its been little while, as i have said before i wanna get the bodywork mint before i do anything else. Been out to the "Garage" tonight with Mark. removing more shit from engine bay, wiper motor, brake servo, ABS, writing loom and alarm! Also been sanding and grinding rust down, which luckly was mainly surface. still deff needs front floor after further investigation (see pictures) After Mini is sold (last day on e-bay 2moz and met reserve) the astra will be in "full swing" to say. got holes in all the normal places, under brake servo isn't to bad but the drives floor is worse but i knew it was "going" just not that bad!


http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0976.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0977.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0978.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0980.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0981.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0982.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0983.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0984.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0985.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0986.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0987.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0988.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0989.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0990.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_0991.jpg

Once again thanks Mark!

[MK2-JOHN]

I always thought that the "hole" under the air box was meant to be there on fuel injection models, due to the air box needing to have an air feed, which is normally a plastic section of corrigated tube running from the lower section of the air box, through the "hole" & mounted @ the rear of the front bumper.

The project seems to be coming along quite well mate, & you seem quite confident in your apprentice skills with you only being 19,
Keep us updated with this one, should be nice when its all done if you put as much effoert in the re-build as you have with the strip down(bow)


(P.S, keep it white):thumbsup:

[Dale]

well i dunno i had a black box near oli cooler which the airbox was connected to! i dunno if it is there to keep the noise of induction down!
Thank you i am quite confident i will be fully trained in December this year, passed all 1st years tests with flying colours! so lets wait and see! still got alot to learn about the 20let conversion, getting there tho!
Yer i always wanted a mk2 since mums ex had one and took me out in it! so i am taking my time and making the car i always wanted to own. def won't be rushing with this car!

yer i wanna keep it white and get it white underneath too as i am a bit of clean freak and will only use it on dry days! altho i like estral blue from the E46 BMW's!

[Mjl16vGTE]

It looks a nice strait example! Not too much rust which is good, You have stripped it down which is a good idea if you want to keep one of these as rust will kill them overwise! Nice job well done!! keep up the good work!

[Tom]

Nice project to keep yourself busy with, its got all the usual rusty bits, have seen alot worse though !

That hole your on about is open on the 8v gtes for the air ducting from behind the bumper to the airbox, its closed on the 16v.

When you come to sorting the holes in the bulkhead next to the steering rack mount, Id advise you seem weld the rack mount and put some extra plates in to beef up that area, have a look in my project turbo thread for pics ;)

Keep up the good work matey :thumbsup:

[Dale]

ah cheers for the info about that hole Tom.
Yer well i am planning on stitch welding the engine bay and making strengthen plates around there and steering rack and maybe around the shocker turrents. i wanna build it too last! Yer i always read your's topic and other turbo topics on here to compare and see the best ideas, love your car btw Tom. cheers once again. :)

[GazJevs84]

good work fella

[Dale]

Well the weathers been getting better, so i thought i would crack on with the astra again, so i rolled it out garage, first time since last year because it was on axle stands!

bought few new things:

mk3 Astra 1.7d Rad (i been told this is the best one for Let conversion?)

Spax 40mm lowering spring (got 25mm on ATM)

Rear Arches repair pannels


Stuff i did:

Removed last bits pf the wiring harness and other bits

Grinded alot of the rust patchs back and sprayed over to stop further rusting until i get it to bodyshop later this year!

Removed half the sound shit stuff!

Few Pictures:

http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1054.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1055.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1056.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1057.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1058.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1059.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1060.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1061.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1062.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1063.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1064.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1065.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1066.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1067.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1068.jpg

[mick g]

Good stuff Dale go and attack that rust stuff, seek and destroy!:grinning-smiley-043

[Dale]

well its been a while since i updated this and i haven't been to the astra! I know i should have but i been busy selling my Mini which i got £2,700 for in the end and the money will be going towards the astra. now i can finally get on with buying the LET, intercooler and getting the welding done even a small deposit to the bodyshop! here are a few things i bought because i couldn't miss out on them!

i bought this because someone drilled through my blanks to put a shitty cilford in

http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1145.jpg

Got these babys on eBay earlier this year for £27.50 which i didn't think was bad still brand new not opened.

http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1146.jpg

Spax 40mm lowering springs (next to standard ones) already got koni adjustable shocks

http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1337.jpg

electric sunroof motor :bananajump:

http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1338.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1339.jpg

And finally the rear arch's

http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1340.jpg

I will be ordering the front wings, drivers floor pan and sills from beavers in the week.

[mick g]

Well done dude:)

[Trabantman]

Great job !!
How are you guys fixing the rust on the bottom below the pedals ?

[Dale]

i going to cut all rust out and plate it if your are on about under the brake servo and put a new floor pan for the floor!

[Trabantman]

Allright like the same i thid if i understand you right.
I`ve you would like to see pics how to or how it looks when you replace everything i can put them on for you .

[Dale]

Well i treated the astra and bought its new heart off the guy thats bought Valvers Let, so Valvers Let will live on in my astra! i am picking it up on sunday and i will post some better pictures. also posted a few of what it was like in Valvers car!

Also bought some Steel Rods with ARP bolts from the MIG group buy :grinning-smiley-043

http://i40.photobucket.com/albums/e210/Scotchy11/Astra/DSC00147.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/DSC00146.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/DSC00145.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/DSC00144.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/DSC00143.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/DSC00141.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/DSC00137.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/ebay018.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/ebay013.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/C20XErodsmallend.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/C20XErods.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/C20XErodbigend.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/C20XErod.jpg


i am not sure if i will use the intercooler, as the inlet and outlet are on the same side, surely making the flow bad and i want a nice polished one! What do you guys think?

Cheers Dale

[Ian T]

Nice update, I'm thinking this is going to be one of my favourite cars when it's done. :)

Ian.

[Dale]

well, i went for a long drive to harlow yesterday 3 1/2hours from swindon and i picked this up :)

http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1342.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1343.jpg

engine stand for now, i made

http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1341.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1344.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1345.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1347.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1348.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1349.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1351.jpg

and the old and new together

http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1352.jpg
http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1353.jpg

Here is the outer shaft for the equal length one is this correct?

http://i40.photobucket.com/albums/e210/Scotchy11/Astra/100_1354.jpg

Cheers Dale