Danny's Astra

[Danny]

Posted about this before, but time to start a new thread to mark the start of the work.
My Astra 16v needs some welding work so I have a solid base to work from as I want to build a track day/road car.
My local garage kindly let me put the Astra on their lift on Saturday (November 4) to asses the rot.
Not too bad, but also noticed a split driveshaft gaiter plus the rear brake pipes need replacing, which will be done this week.
The work won't be done until January because the MOT is due on November 13 and there is no way it will pass.
To get round this, the car will come off the road and stay at my mates place until he gets the chance to sort it.
Also included a gratuitous shot of my ride on the ramps.
Will post pics as and when the work is done.
If anyone has a tax and tested runabout for about £400, and is in/near Kent please PM me.
Take care, dudes and dudettes. :thumbsup:


http://i47.photobucket.com/albums/f176/Astra131/th_100_0246.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0246.jpg)
http://i47.photobucket.com/albums/f176/Astra131/th_100_0245.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0245.jpg)
http://i47.photobucket.com/albums/f176/Astra131/th_100_0244.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0244.jpg)
http://i47.photobucket.com/albums/f176/Astra131/th_100_0243.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0243.jpg)
http://i47.photobucket.com/albums/f176/Astra131/th_100_0242.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0242.jpg)
http://i47.photobucket.com/albums/f176/Astra131/th_100_0241.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0241.jpg)

[BazW]

seen (and owned) worse mate :)

[Danny]

Thanks, Baz.
Yeah, it's not as bad as some so I'm lucky.

[MK2-JOHN]

not looking too bad there danny, as baz said..owned & seen much worse, at leasts fixable :thumbsup:

[BazW]

my first GTE I took the skirts off and there was no sill. the only thing holding them on was the self tappers either end, the paint was just about holding the rust together :)

[Sipo]

Aye, she doesnt look too bad, but a great time to hop onto it as its starting :)

Good luck, is this one mistral grey or silk violet? Cant tell from the pics.

[DarrenH]

familiar looking rot there ! although my inner sills werent "as" bad.

dont want to be a misery monger, but if the inner sills are like that, then theres probably free air conditioning system hiding under your side skirts!!

amazed ive still not seen you around, is it your daily driver ?

[mking]

doesn't look too bad there. real nice colour aswell, looks mistral to me? :)

[Danny]

Thanks for comments lads.
I'm not sure whether it's mistral or silk violet to be honest.
Pretty sure it's Mistral.

Oddball.
The car is my daily driver and gets used pretty much everyday.
However, not being used today because it's got a suspected shot head gasket.
Checked expansion tank yesterday and nearly all the water had gone.
There were no obvious signs of leakage from pipes so can only think it is the head gasket.
Gonna get it sorted this week along with split nearside driveshaft gaiter and replace the rotten rear brake pipes.

Thanks for the words of support. :thumbsup:

[BazW]

However, not being used today because it's got a suspected shot head gasket.
Checked expansion tank yesterday and nearly all the water had gone.
There were no obvious signs of leakage from pipes so can only think it is the head gasket

check the water pump first, before mine went I was topping it up once a week. mine was loosing coolant with no obvious leaks and it wasn't until I ran a radiator flush through it that it went properly. it was leaking for ages but evaporating before it got to the floor so there was never a puddle

[Danny]

Thanks Baz.
The car had a new water pump in February this year, so might not be this.
Got a mate who works for Vauxhall's looking at the old girl tomorrow anyway, so hopefully should all be sorted V soon.

[Danny]

Finally said goodbye to my Astra for a while after dropping it off at my mate's.
Work probably won't start until mid January because he's got a lot and doesn't do bodywork for a living.
Anyway, this is the Astra at my mate's Tony's.
http://i47.photobucket.com/albums/f176/Astra131/th_100_0257.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0257.jpg)

And this is one of his projects to give you an idea of the sort of stuff he takes on.
I know it's a beetle but he loves em, and each to their own.
http://i47.photobucket.com/albums/f176/Astra131/th_100_0258.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0258.jpg)

In the meantime I have bought an Austin Metro as a runabout which I will post pics of soon so you can take the Pi55.

I don't care tho, it's cheap and unlike the astra is not a joyrider's favourite.

[Danny]

The project's starting to gain pace. The Astra was moved from its storage on Saturday, April 14 and transported to another bodywork dude I know after my mate who was gonna do the work, couldn't.

After a quick assessment of the car, my bodywork dude found that when he opened the driver's door to its full extent, then pushed it a little more, there was too much movement on the A post.

This happened on both doors and means there is lots of rot. Not good.

Apart from tidying the offside arch, dent in the nearside wing and bubbling on the roof, there isn't anything else to do.

TBH it's make or break time (literally). If the repairs run into silly money then I'm gonna have to face facts and break the car.

If it can be done, next on the list is this:
Full service
MOT
TAX
Snap off steering wheel
Aftermarket gaitor, gearknob and pedals.
Eventually it will be stripped out with two bucket seats.

Here's some pics.
http://i47.photobucket.com/albums/f176/Astra131/th_100_0659.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0659.jpg)


http://i47.photobucket.com/albums/f176/Astra131/th_100_0658.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0658.jpg)

[bigdrifter]

Very nice looking car, shame if the rot is terminal

[James C]

I hope it will be ok!

Brightside though, if not you can get another, and the current one will live on in donor bits.

Its the sad reality of Mk2 ownership :(

[Dale]

fight the rot mate!

[DarrenH]

i dont think bending the door back beyond its mechanical range, is indicative of how much cassis rot there is.

bit of an odd test, you sure this guy is ok ?

i cant recommend M.A.S car and commercial highly enough, they are down the eurolink, behind the smead dean centre/ old calor gas shop. they did all the work on my gte and it was top notch. head honcho mike sellars is a top bloke too, drives his self prepared car in the british rally cross championship !!

[Danny]

Thanks for the replies.

Hopefully it won't be too bad, I'm just preparing myself for the worst.
TBH everyone else's projects gives me the confidence to carry on. People on this site are taking on much worse examples, but still building great cars.

Oddball.

I trust this guy implicitly as I have seen examples of his work. However, thanks for recommending the place on the Eurolink.

TBH, I think he was checking the rot around the A post. Let's face it, if the post has a lot of movement, then presumably it is either not fitted properly or is rotten in other areas. Either way, it needs attention.

Will be posting pics of the rot V soon.

Danny.

[DarrenH]

well from my knowledge, the car half of the door hinge is delibarately not welded solid as it tends to crack very easily in places where there is allot of flex

[Danny]

Fair enough Oddball.

Maybe the guy was just being overcautious.

It's also reassured me that the rot may not be that bad.

TBH this is one of those situations where I wish I could introduce you to the guy so he could explain himself.

As I say, I still trust him and you should see pics of his work soon.

Thanks for your interest. Oddball.

[Danny]

Bought some new sills for the Astra this week.

Wanted to buy both from Hadrian, but they only had one side so I bought another from SSVG.
Both were purchased from Cat Automotive in Sittingbourne (01795 479531)
Collected them today. Bit disgruntled because they weren't protected at all, and had a bit of a grumble at the guy but was told this is how they always arrive. Checked 'em over and they seem OK.

The brown one is from Hadrian and cost £14.10 and the SSVG one cost £21.80.
Total with VAT £42.19

http://i47.photobucket.com/albums/f176/Astra131/th_100_0948.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0948.jpg)http://i47.photobucket.com/albums/f176/Astra131/th_100_0947.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0947.jpg)http://i47.photobucket.com/albums/f176/Astra131/th_100_0946.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0946.jpg)
http://i47.photobucket.com/albums/f176/Astra131/th_100_0945.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0945.jpg)http://i47.photobucket.com/albums/f176/Astra131/th_100_0944.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0944.jpg)http://i47.photobucket.com/albums/f176/Astra131/th_100_0943.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0943.jpg)
http://i47.photobucket.com/albums/f176/Astra131/th_100_0942.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0942.jpg)http://i47.photobucket.com/albums/f176/Astra131/th_100_0941.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0941.jpg)http://i47.photobucket.com/albums/f176/Astra131/th_100_0940.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0940.jpg)
http://i47.photobucket.com/albums/f176/Astra131/th_100_0938.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0938.jpg)

The sills in the mighty Metro ready to be delivered to my bodywork man tomorrow. Ignore the TV in the boot. It's destined for the tip.
http://i47.photobucket.com/albums/f176/Astra131/th_100_0949.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0949.jpg)

Also bought a new towing eye cover from Vauxhall a few weeks ago which cost £25.09
http://i47.photobucket.com/albums/f176/Astra131/th_100_0765.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0765.jpg)
http://i47.photobucket.com/albums/f176/Astra131/th_100_0763.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0763.jpg)

Here is how the car is usually seen these days. Should be back on the road soon.
http://i47.photobucket.com/albums/f176/Astra131/th_100_0425.jpg (http://i47.photobucket.com/albums/f176/Astra131/100_0425.jpg)

I plan to use a mixture of new and second hand parts to tidy the GTE, although want her to look good which is why I've sometimes opted for new stuff.

Hopefully be posting some pics of the bodywork being done soon.

Chow for now.

[mick g]

Its the start of the long and windy road with the sills. Beat that rust!

[Danny]

Thanks for the reply Mick and nice meeting ya mate at PVS.

Dropped sills off today. My bodywork dude said the Hadrian panels are a good fit, so I just hope the SSVG ones are as good.

[Danny]

Quick update to show you all what I have bought for the GTE.

It's a Momo Pilota 2 steering wheel from Demon Tweeks and cost £79.99.
I also purchased a Snap off kit for it at the same time which cost £96.10 which came with a fitting kit for the Mk2 GTE that cost £9.42.

This totalled £185.51. Add the cost of P&P AND VAT and the total was £215.

A lot money I know, but if it helps stop some scumbag nicking my GTE then it's money well spent IMO.

BTW, the wheel size is 350mm

http://i47.photobucket.com/albums/f176/Astra131/100_1100.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1099.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1098.jpg

Also found this cubby hole from a Daewoo at the scrappy yesterday.
Will it fit my GTE 16v?
http://i47.photobucket.com/albums/f176/Astra131/100_1112.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1111.jpg

I told the dude who's doing the bodywork I want her done for Sept 22, which is the Mk2.com Santa Pod day, and he said it should be done in time.
I'm keeping everything crossed it will be. :thumbsup:

NB Moderators: I'm a paid member, so can someone please adjust my signature to suit please. Thanks, Danny.

[Mick8v]

Nice looking car Danny, doesnt look too bad, good to see its getting some tlc good luck with it, nice to meet you at pvs btw.

[Danny]

Thanks for the praise, Mick.

Hopefully it will be done in time for Sept 22.

[richie00boy]

That's a good price for a Momo wheel. They were wanting not far off that at Billing for some cheap make weren't they?

[Danny]

Were they Richie? I missed those ones.

IIRC Demon Tweeks were having a sale, which is why the price is pretty good plus being a snap off it gives real peace of mind.

[richie00boy]

Yeah don't you remember that stand we looked at the steering wheels? Richbrook they were.

[GTEGirl]

When you were looking for your mats.... you looked at loads of wheels!!!!

[Danny]

Oh yeah. God what a numpty I am at times. I remember now. :duh:

[astrayorkie]

the snap off kit is a good idea i have one on mine, When it was on my old car used to take it off when going in to cinema ect and you don't halve get some looks lol!!

[GTEGirl]

the snap off kit is a good idea i have one on mine, When it was on my old car used to take it off when going in to cinema ect and you don't halve get some looks lol!!


Bit of a status thing in the 90's to carry yr stereo face into the cinema.... a wheel brings it itnto a whole new era!:applause:

[Danny]

I had a snap off on my old GTE 8v and did get some strange looks when I took it off.

My nephew, who was about four at the time, used it to pretend he was driving a real car around the front room! :veryhappy:

[Ian T]

Bit of a status thing in the 90's to carry yr stereo face into the cinema....

Now that brings back memories, lol. :o

Oh and the ultimate then was the logic control tape deck, which was promptly outdone by the Pioneer 6 disc multiplay CD changer.

Incidentally, I'm recreating all of that in my GTE and have bought a 90s Pioneer head unit and CD changer, simply because they were so good for their time.

I'm looking forward to seeing this car of Danny's when it's done - I ought to be able to make the Pod weekend, wasn't going to be free, but think I am now, so that'll be it then. Get it done! ;)

Ian.

[Danny]

After a sneak preview in General Chat, here are the resto pics in more detail.
Outside the car didn't look too bad.
Underneath there was some serious rot.
It's debatable whether it was worth saving. However, I didn't have x-ray vision when I bought it, and you don't know what you are getting with these cars until you pull them apart.
At least I know where all the rot is now.

Pic of car before work started.
http://i47.photobucket.com/albums/f176/Astra131/100_1368-1.jpg
After lower rear arches had been fitted.
http://i47.photobucket.com/albums/f176/Astra131/100_1392.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1389.jpg

Before
http://i47.photobucket.com/albums/f176/Astra131/100_1358.jpg

After.
http://i47.photobucket.com/albums/f176/Astra131/100_1388.jpg

Before. Instead of fixing the A post properly, it had been bodged. Look carefully and you can see spot welds, where fresh metal had been welded to rusty metal. In fact most of the work on the car had been done badly.
http://i47.photobucket.com/albums/f176/Astra131/100_1370.jpg

After. The inner part of the A post was rebuilt from scratch. I supplied the outer skin (Hadrian part. cost £13.60) which was fitted.
http://i47.photobucket.com/albums/f176/Astra131/100_1387.jpg

Rotten door.
http://i47.photobucket.com/albums/f176/Astra131/100_1366.jpg
Sorted. A new piece of metal was fitted to connect the door panel to the the
lower part, so there's not much filler. Needs sanding and painting.
http://i47.photobucket.com/albums/f176/Astra131/100_1384.jpg
Both doors have been de-locked.
http://i47.photobucket.com/albums/f176/Astra131/100_1381.jpg
A panel will be fabricated from scratch to mend the floor.
http://i47.photobucket.com/albums/f176/Astra131/100_1383.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1382.jpg

http://i47.photobucket.com/albums/f176/Astra131/100_1363.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1360.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1359.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1380.jpg

The car has had two new sills, one Hadrian which cost £14.10 while the other was a different make, (can't remember who) and cost £21.80.
Both lower rear arches have been replaced with Hadrian items. One was £15.60 and the other, strangely, was £10.90. Unfortunately the receipt doesn't specify which side is which, so I cannot say which side was more expensive.

There's still a few small areas which need attention, but this will have to until next year.
These are rust on the front of the offside wing and bubbling at the spoiler mounting points and on the lower edge of the boot.
It seems a shame not to get them done now, but my budget will not stretch to it.
More pics to follow soon.

[Danny]

Forgot to add.

I have decided not to put the plastic sideskirts back on as they are a water trap.

[richie00boy]

If you are on about the front wing I wouldn't worry about it as they are just bolt on. I'd like to see the front bumper mounts done though, not sure if that's on the list?

[Danny]

If you look on the 5th picture down, there's some rust on the body above the mounts. That's where I meant.

Actually Richie I think it is the bumper mount, sorry I should have used the correct name.

No it is not on this year's list. Will have to wait until next year.

[MK2-JOHN]

Christ Danny, i thought i had my work cut out for me with my GTE, i feel loads better now after seeing how bad yours was and how good it will be

big respect for saving a car which was in such bad state where others would have given up

[DarrenH]

coming along brilliantly mate :)

not teaching granny to suck eggs, but can you remind mr body shop that he has welded over the door drains with that new bit of metal along the bottom. that will cause you big trouble in a few months.

[Danny]

Thanks for the comments.

Good spot Darren. Will raise the door drain issue next time I visit the dude.

How do you rectify the problem?

I've had enough of frigging leaks as you can see, and want the car to be bloody water tight for once.

[DarrenH]

you can see the rear drain in the "before" picture. its a slot shape.

[Brett]

thats the worst shape A pillar I've ever seen!! No doubt the situation was made worse by plating over the top of rusty metal already by a previous owner, but **** me!!

[Danny]

Thanks Darren. I'll get this sorted.

Yup. A post was pretty bad, Brett.

Looking at all the rot on the car it was lucking the drivers seat didn't fall through the floor plus I think the passenger door was being held on by a wing and a prayer.

Going the right way now though.

[Danny]

It's back! :Banane44: :Banane44: :Banane44: :Banane44: :Banane44:

Picked it up from the bodyshop on Friday, October 11.
Your gonna have to use your imagination a bit with these pics though.
The car had only just been finished and stood outside for the afternoon, plus it had been raining.
The day was also overcast, so the light was rubbish.

Everything has been resprayed apart from the front bumper because this wasn't part of the deal and will be done soon.
Bumper inserts were not sprayed either. I will do them myself asap.
However, all the major rot has now been fixed.

BTW Darren, I checked the query you had and the picture was of the old sill. New sill is as Vauxhall intended. Problem solved.

Work involved replacing/sorting.

Rotten nearside lower A post.
New sills both sides.
New lower rear arch body panels fitted.
Underside of driver's door sorted (very rotten).
Offiside floorpan sorted. (bye bye big holes in floor.)
Bubbling near sunroof sorted.
Holes in nearside front wheelarch sorted.

Plastic sideskirts removed and will not be re-fitted as they are water traps and inhibit rust.

Jobs to do.

Service.
Fit snap off steering wheel.
Fit Daewoo rear quarter trims.
Fit new windscreen. (Old one has lots of scratches which pi55e5 me off. New one will look a lot better.)
Fix puncture in offside front wheel.
MOT
TAX
Scrub interior.
Wash and polish exterior.

Only have weekends to work on the car, but should be alll sorted within next three weeks. Will keep you all updated.

Imagine the car washed and polished on a sunny day and you should get the idea.
http://i47.photobucket.com/albums/f176/Astra131/100_1404.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1403.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1402.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1399.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1398.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1397.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1396.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1394.jpg

Before
http://i47.photobucket.com/albums/f176/Astra131/100_1370.jpg
After
http://i47.photobucket.com/albums/f176/Astra131/100_1405.jpg

How the car looked at the Retro Show last year. You just don't realise how rusty these cars can be on the inside.
http://i47.photobucket.com/albums/f176/Astra131/100_0148.jpg

[astrayorkie]

:thumbsup: looking good dude

[DarrenH]

i was on about the lower lip of the door mate, clearly. not the sill. hes blocked the drain holes with the new strip welded in, youll have 2 litres of rain water slopping about in there with no p[lace to go, the next time it rains!

the pics of the finished article look awesome!!

[DarrenH]

drain hole!

http://www.oddball123.pwp.blueyonder.co.uk/carstuff/100_1366.jpg

no drain hole!

http://www.oddball123.pwp.blueyonder.co.uk/carstuff/100_1384.jpg

[bigdrifter]

As Darren said, get the drill out sharpish before the door fills up. Certainly looking much healthier now - have never seen an A pillar so bad on a modern(ish) car

[James C]

Looking good - I still have mine and there is some drag racing to be had on 28th Oct so I hear!

:grinning-smiley-043

[Gteman]

Loving it :thumbsup:

As above sort out those door drains as water is expected to get by the window seals and you are locking it in.

The A post is/was in some mess I had a good prod about mine at luckly was ok, though now Im having some doubts.

[Danny]

Apologies Darren.

Misunderstanding on my part. Thank you for pointing it out with the pics.

I presume I can simply drill some small holes in the underside of the door to sort the problem?

James.
A service, tax and MOT is all that's holding me back from the strip.
MOT being sorted next week so I'll let you know dude. :thumbsup:

I'm really happy with the work. It's so nice to see all the rust fixed and have a solid base to build on.

That A post was not only previously fixed by bodgit and scarper Ltd, but was also THE worst I've ever seen.
I hope it doesn't put people off buying these cars, you just have to expect rot with motors of this age.

[Danny]

Did a bit more on the Astra today.

Changed the plugs, leads, oil and filter along with the petrol filter.

Hoovered the boot and cleaned the dashboard as well.

I had to change the AFM for a spare because the garage who are doing the MOT said they could not adjust the mixture.
I think the one I stuck on there works, if not I'll put a post in the wanted section.

One of my neighbours saw me working on the car and came over for a chat.
Turns out his son is building a drift car out of a Nissan 200sx.
He's a top man and also has a workshop which he said I could use if I wanted.
It's handy to know someone nearby who could help with tools/knowledge
etc.

On a downside, there's been a spate of numbnuts smashing car windows in my area.
Great, just as I get the Astra back, these idiots appear.
I've no idea who it is, but do know that if they touch my Astra I will smash them.

Some pics.

One of my old spark plugs. Looks like the engine's running a bit rich.
http://i47.photobucket.com/albums/f176/Astra131/100_1415.jpg

Rear brake pipes were replaced by a local garage.
http://i47.photobucket.com/albums/f176/Astra131/100_1427.jpg

Got a bit worried when I saw this. However, after checking the water, I realised it is just condensation where the car has been standing for over a year. Not surprising really.
http://i47.photobucket.com/albums/f176/Astra131/100_1426.jpg

Treated myself to this oil filter tool. Easier and cleaner than the old trick of using a hammer and screwdriver.
http://i47.photobucket.com/albums/f176/Astra131/100_1420.jpg

The old skirts are for sale. £20. PM me if interested. Will post in for sale section.
http://i47.photobucket.com/albums/f176/Astra131/100_1418.jpg

My ideal Sunday. Messing with the Astra. Weekends are so much more exciting now it's back.
http://i47.photobucket.com/albums/f176/Astra131/100_1417.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1423.jpg

After using four of these my dash now looks like this........
http://i47.photobucket.com/albums/f176/Astra131/100_1435.jpg

http://i47.photobucket.com/albums/f176/Astra131/100_1438.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1437.jpg

Also bought a new bucket which I will only use for the Astra and one of those wash mitts as recommended in the car detailing section.
http://i47.photobucket.com/albums/f176/Astra131/100_1444.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1442.jpg


Ah yes, and finally my little helper. This is my friend Amanda who moved in nearby a while ago.
Have spoken about her before on here. Unfortunately there's not gonna be any between the sheets action. Long story. We're just friends.
She made me tea all day and a sandwhich at lunchtime. She even passed
me the correct socket when I changed the oil. All in all, not a bad neighbour.
http://i47.photobucket.com/albums/f176/Astra131/100_1421.jpg

[richie00boy]

Good work Danny. At last a fellow matt dash fan :thumbsup: Where did you get those matt wipes? I can only ever find horrid gloss ones.

Had to read that last post twice, I missed the "nearby" the first time around and was thinking you sly old fast mover! :)

[BazW]

fresh paint :D

looking good, anymore plans then?

...and from that pic i think she likes you more than she's letting on btw ;)

[exclusivemark]

...and from that pic i think she likes you more than she's letting on btw ;)[/QUOTE]

Agreed :gossip:

[Danny]

fresh paint :D

looking good, anymore plans then?

...and from that pic i think she likes you more than she's letting on btw ;)

Yes Baz. Next up is an MOT, new alarm being fitted this Saturday then a good scrub of the interior and wash and wax the exterior.

Also gonna fit a snap off steering wheel.

The front bumper, bumper inserts and front and rear splitters should be sprayed by Christmas.

Rear spoiler has a couple of runs which my bodywork dude apologised for and said he would re-spray it again for free.

Long term plans are to strip it out, fit two bucket seats, a rollcage and LET.
I want to use it for track days eventually.

Amanda's a bloody tease, I wouldn't pay too much attention to that pic.

[Danny]

Good work Danny. At last a fellow matt dash fan :thumbsup: Where did you get those matt wipes? I can only ever find horrid gloss ones.

Had to read that last post twice, I missed the "nearby" the first time around and was thinking you sly old fast mover! :)

Sorry Richie, forgot to add.

I got the wipes from my local Halfords.

I prefer matt because gloss makes the dash reflect too much in the windscreen.

[Danny]

...and from that pic i think she likes you more than she's letting on btw ;)

Agreed :gossip:[/QUOTE]

Hi this is Amanda, (logged in as Dan) Dan's neighbour.
For your information Yes I do like Dan but not in that way, it is possible for man and female to have a friendship without any sex involved, but sorry ur blokes and don't know that things happen outside of the bedroom.

Although u can't blame him for wanting me lol
Bye!!!
x

[BazW]

Hi this is Amanda, (logged in as Dan) Dan's neighbour.
For your information Yes I do like Dan but not in that way, it is possible for man and female to have a friendship without any sex involved, but sorry ur blokes and don't know that things happen outside of the bedroom.

Although u can't blame him for wanting me lol
Bye!!!
x

oops, my bad

we're a romantic lot on here and thought young daniel had found a soul-mate, somebody who could share his love of country walks and poetry with

apologies if we got you in bother

[Danny]

oops, my bad

we're a romantic lot on here and thought young daniel had found a soul-mate, somebody who could share his love of country walks and poetry with

apologies if we got you in bother

Ha ha.

You didn't get me into any trouble dude.

She actually asked me if anyone had replied to her photo. When we realised people had she wanted to reply to them.

She's fine and I'm not in trouble. Amanda's cooking me dinner tomorrow and then we're going bowling so it's not that bad.

[DarrenH]

did you fit the mk3 gsi steering wheel and stalks ?

[GazJevs84]

:applause: Cars looking good bud

[Danny]

Another couple of weekends and a bit more done.

My time is limited at the mo, but she should be MOT'd and ready for the road by the end of next week.

The Astra needed a another Air Flow Meter for the MOT, as the garage couldn't adjust the one on it for the emissions.

I found another at a breakers and picked it up today.
It had the same part number as the one already on the car. Is this a bizarre coincidence?
Anyway, breaker's AFM still had the plastic cap for the adjustment screw attached.
IIRC the screw adjusts the air/fuel mixture.

Here's what I mean.

My old AFM is on the left with screw exposed. Newish AFM on the right still has the plastic cap for the screw, which I presume is how it came from the factory. It cost £30.
http://i47.photobucket.com/albums/f176/Astra131/100_1480.jpg

To remove the cap, I fixed a screw in the cap and pulled the screw out with a pair of pliers which removed the plastic cap at the same time.
http://i47.photobucket.com/albums/f176/Astra131/100_1496.jpg

Removed cap.
http://i47.photobucket.com/albums/f176/Astra131/100_1497.jpg
I've fitted the newish AFM to the Astra. Hopefully the emissions can be adjusted now as this was the only thing stopping it from getting an MOT.

Also fitted a new gearknob. I know it's a bit bling and is a Ripspeed item, but I've had it lying around for ages and I like it, so there.

Before.
http://i47.photobucket.com/albums/f176/Astra131/100_1466.jpg

During.
http://i47.photobucket.com/albums/f176/Astra131/100_1474.jpg

After.
http://i47.photobucket.com/albums/f176/Astra131/100_1475.jpg

When I'd finished playing with my knob I went to Halfords and bought this to spray my rear drums with.
http://i47.photobucket.com/albums/f176/Astra131/100_1502.jpg

As most people know, when you mess about with cars, it's a good idea not to throw anything away. Hence the reason for this can of bits.
http://i47.photobucket.com/albums/f176/Astra131/100_1503.jpg

From this pile of random clips, screws etc I manged to glean these, which will ensure my door cards and trim fit snugly.
http://i47.photobucket.com/albums/f176/Astra131/100_1504.jpg

Also found a few Jubilee clips, which was handy.
http://i47.photobucket.com/albums/f176/Astra131/100_1506.jpg

I also decided to cut the metal rod which the door pin fixes to, so thieving scum cannot prise the door open and unlock the car by lifting the pin.
Despite having a Cat 1 alarm fitted last weekend (not saying which one for obvious reasons) I still want to do what I can to make life hard for pikey to55ers.
The car doors have been de-locked, but the boot lock retained, so if the door motors which unlock/lock the doors fail, I still have a way in.

I found a piece of trim to fill in the hole after removing the pin and plastic trim within the door card.
Before
http://i47.photobucket.com/albums/f176/Astra131/100_1507.jpg
After
http://i47.photobucket.com/albums/f176/Astra131/100_1512.jpg

Sorry the pic is a bit blurred, my camera cannot do close ups. If you can identify this, please let me know what it is as I only have one. This is what I used to fill the hole in the door card.
http://i47.photobucket.com/albums/f176/Astra131/100_1510.jpg

I also found this. Anybody know what it is?
http://i47.photobucket.com/albums/f176/Astra131/100_1487.jpg

More to come next weekend.

Advice needed.
Although the emissions need adjustment,the car runs fine. However, it has been sitting idle for about 14 months.
Is it worth putting some form of engine flush treatment to clean out any cobwebs? If so which one?

Darren H.
I have already fitted Mk3 stalks. Not fitting a GSi steering. A Momo Pilota 2 with snap off boss will be going on there.

Thanks for looking.
The other projects on here really inspires me to crack on with mine. :thumbsup:

[Mick8v]

Looking good there Danny, liking the pin plugging wotsit it finishes it nicely, that part looks like the coolant temp sensor for the dash temp gauge, it usually resides in the thermostat housing

[GTEGirl]

:applause: :applause: :applause: :Banane47: All that feet dragging looking at steering wheels was worth it! Looks stunning..... :applause:

[Danny]

Thank you Mick and GTE Girl.

GTE Girl. That long walk we went on during Billing was well worth it, cos those Vauxhall mats I bought will be a nice finishing touch.

[BazW]

coming along nicely there danny, looking forward to seeing it finished

btw i'll be borrowing your idea of the black rocker & cambelt covers for my 16v, i reacon it suits the mistral grey on yours. hope you don't mind :)

[GTEGirl]

Thank you Mick and GTE Girl.

GTE Girl. That long walk we went on during Billing was well worth it, cos those Vauxhall mats I bought will be a nice finishing touch.


Forgot the mats! Yep, will look ace! good on you! :grinning-smiley-043

[richie00boy]

Good work Danny. As said that sensor is the dash temp. Not sure what the blanking grommet is off.

If the car has been stood a long time just give it a little run then change the oil and coolant and take it for a good run. Shouldn't need any more than that :thumbsup:

[DarrenH]

coolio!

that screw on the AFM does adjust *idle* mixture on non cat cars, or CO pentiometre to give it its official title!. on cat/lambda equipped cars the loom for the adjuster is not connected at the ecu end so it makes no odds.

also, its got a tamper proof cap because its factory preset. it shouldnt need adjusting, and if it does you will probably be overcompensating for some other mechanical or electrical fault.

[Brett]

wow mate this has come a long way since I last looked!

Regarding the removing of the door pins, I did the same on mine and found after that there was no way of lcoking/unlocking the car if you are in it without using the alarm, so I fitted a little micro switch from Maplins to allow me to do it and conceeled it out of sight. Harvey actually thought of it:)

[Danny]

coming along nicely there danny, looking forward to seeing it finished

btw i'll be borrowing your idea of the black rocker & cambelt covers for my 16v, i reacon it suits the mistral grey on yours. hope you don't mind :)

It was painted when I bought it Baz. Please borrow away. :thumbsup:

Thanks for the replies.

I'll probably borrow your idea of the micro switch Brett, so thanks for that.

BTW, the car passed its MOT today :bananajump: :bananajump: :bananajump:

I was given an advisory about a slightly corroded fuel pipe, but the garage cleaned it up and said the pipe won't need replacing for a few months yet.
However, I'll get it sorted by Christmas for peace of mind.

I plan to polish the car next weekend and take some pics which I will, naturally, post on here.

Thanks for looking. Can't wait to show her off at the Westerham meet on November 25. :thumbsup:

[richie00boy]

Doesn't your alarm fob control the central locking? i.e. when you are driving the car and want to lock or unlock the doors just press the fob button. The alarm knows the ign is on and just locks the doors not alarming the alarm.

If you want to sleep in the car then you can set the alarm by a fob button combination so that the sensors are disabled.

[Danny]

Doesn't your alarm fob control the central locking? i.e. when you are driving the car and want to lock or unlock the doors just press the fob button. The alarm knows the ign is on and just locks the doors not alarming the alarm.

If you want to sleep in the car then you can set the alarm by a fob button combination so that the sensors are disabled.

Your right Richie. However, if I lock the car and the motors fail for whatever reason, say a flat battery, I won't be able to open the doors as it's all done by the alarm fob.

That's why I kept the boot lock. I will be able to open both doors from inside, but for security reasons, don't want to say how.

[richie00boy]

Oh I wasn't on about the boot lock (I kept mine for the exact same reason), I was meaning you don't need to fit a microswitch to unlock the doors from inside the car, if your alarm is anything like mine.

[Danny]

Unlocking/locking the doors Richie is done via the alarm.

If the motors on the door locks fail the doors won't open.

If this happens, I can get in through the boot and unlock the doors this way.

Erm, this is as much as I know. Anymore than this and I'm confused. :confused:

[richie00boy]

OK the comment was more aimed at what Brett did as I thought you were going to do the same and I didn't think you needed to if you alarm was like mine. Sounds like you know what you are doing :)

[Danny]

Thanks Richie.

As you can see, I still have a lot to learn, but thanks for your comments.

Look forward to seeing you again Rich at a show next year. :thumbsup:

[Danny]

Quick update.

Fixed the side repeaters yesterday. Some numpty (me) wired them up wrong before the car went to the bodyshop.

When it came back, sorting them was a priority.

I also sorted some insurance. £348 Full Com through Highway Insurance with a limited mileage of 6,000 a year.
This was the best I could find and well pleased with it.

I have some time off in lieu next week and hope to finish work at noon on Friday, which means I will have a whole two-and-a-half days to work on the Astra.

I plan to:

1. Fit the snap-off steering wheel.
2. Scrub the interior.
3. Wash and polish.

If it doesn't rain, this will all be done.

[Danny]

Been busy lately, so thought it was time for an update.
This one is a picture junkies dream.

A weekend of rain didn't stop me cracking on cleaning the Astra's inside with Autoglym interior shampoo.

First job was to clear out all the mess I made from fitting the snap off steering wheel. (More of that later) I'd also removed the seats so I could thoroughly clean the floor carpet.
http://i47.photobucket.com/albums/f176/Astra131/100_1587.jpg

Dirty interior
http://i47.photobucket.com/albums/f176/Astra131/100_1560.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1559.jpg

Clean interior
http://i47.photobucket.com/albums/f176/Astra131/100_1597.jpg

And clean rear seats.
http://i47.photobucket.com/albums/f176/Astra131/100_1595.jpg

Back together with everything hoovered and scrubbed.
http://i47.photobucket.com/albums/f176/Astra131/100_1600.jpg

The perfect finishing touch air freshener.
http://i47.photobucket.com/albums/f176/Astra131/100_1622.jpg

This is how the interior looked with standard steering wheel and gearknob.
http://i47.photobucket.com/albums/f176/Astra131/100_1438.jpg

Fitting the steering wheel (a Momo Pilota 2) was easy but, unsurprisingly, taking the old wheel off wasn't.

Whacking the back of the wheel with a rubber mallet didn't work.
A Vauxhall technician I know suggested standing in front of the wheel with the centre nut screwed flush with the column. Then yank the wheel towards you.
I bent the top of the wheel doing this, but it came off within 15 minutes.
http://i47.photobucket.com/albums/f176/Astra131/100_1575.jpg

A tip for anyone doing this job. There's a circular back plate on the old steering wheel. Take this off and use the two prongs to fit it to the back of your snap off boss. This ensures there are no breaks in the electrical circuit so the horn works.

http://i47.photobucket.com/albums/f176/Astra131/100_1604.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1602.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1603.jpg

Job done, sort of.
http://i47.photobucket.com/albums/f176/Astra131/100_1607.jpg

Here's me telling people how to wire it up and I can't get it right myself. I tested the horn by pressing the live against the metal boss and it worked.

Two terminals on the back of the Momo steering wheel are supposed to touch these two metal points on the snap off plate and make the horn work. I can't line them up without the wheel not being straight. I'm probably being stupid and no doubt will occur to me soon what I've done wrong.
The two points on the snap off boss.
http://i47.photobucket.com/albums/f176/Astra131/100_1606.jpg

The wheel locks onto the boss with a special key.
http://i47.photobucket.com/albums/f176/Astra131/100_1608.jpg

Annoyingly I discovered the Astra still leaks in both footwells.
However, I can see where water is coming in on the passenger side and will get this sorted in the New Year.

It's leaking by the rusty bit to the left of the electrical part which I don't know the name of. Look carefully and you can see where the bodywork dude almost set my car alight.
http://i47.photobucket.com/albums/f176/Astra131/100_1556.jpg
Had to mop water from here.
http://i47.photobucket.com/albums/f176/Astra131/100_1555.jpg

There was a small amount of water here on the drivers side. Not sure where this is coming in.
http://i47.photobucket.com/albums/f176/Astra131/100_1588.jpg

I also replaced the distributor O ring that was leaking oil.
On the plus side, the Astra is going really well and never fails to put a cheesy grin on my face.

Last job of the weekend was to wash it.
http://i47.photobucket.com/albums/f176/Astra131/100_1616.jpg

This weekend the drums will be sprayed followed possibly by a polish.

Thanks for looking.

[Ian T]

Always good to get to the bottom of any leaks, and definately worth while thoroughly drying out the rubber sound deadening material before it goes back.

I'd suggest looking at the ends of the scuttle, where rainwater running off the windscreen exits the scuttle into the front wheel arches. On mine, the seam sealer was old and brittle, and there was some evidence of seepage through that seam.

Looks really clean inside now - that's one thing I've never had time to do to mine, really must make the effort next year.

Ian.

[Danny]

Thanks Ian, I'll investigate more at the weekend.

[DarrenH]

good update danny. that steering wheel shenanigans bring back a few memories. not my gte, but my first car (mk2 cav) where i took the nut right off and was thumping the back of the wheel with my forearms sitting in the drivers seat.

one nose bleed and lesson learnt, theres a powerful spring behind the steering wheel lol!!!

some evidence of repair to the drivers footwell there, was that you or previous ? i dont know anyones 16v that hasnt rusted there

[Danny]

You alright Darren?

The repair to the footwell was done earlier this year along with all the bodywork.

Yes, that is a powerful spring on the steering column. I strongly advise anyone taking off a Mk2 steering wheel keeps the nut on until the wheel is loose.

[Danny]

Few more jobs done.

Sprayed the rear drums.
Before.
http://i47.photobucket.com/albums/f176/Astra131/100_1639.jpg

After. (Nearside)
http://i47.photobucket.com/albums/f176/Astra131/100_1643.jpg

Offside.
http://i47.photobucket.com/albums/f176/Astra131/100_1640.jpg

Also replaced the A pillar trim because the old one had this fitting in it for a previous alarm.
Before
http://i47.photobucket.com/albums/f176/Astra131/100_1703.jpg
After
http://i47.photobucket.com/albums/f176/Astra131/100_1705.jpg

Will have to get the rear arches rolled in the New Year as well, because I think they are rubbing. The car's only lowered 35mm, however I think the new arches must have a bigger lip on them than the old ones.
They rubbed when my neice and nephew were in the back, and the kids must only have a combined weight of about 10 stone.

Current clearance on rear arches.
http://i47.photobucket.com/albums/f176/Astra131/100_1632.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1630.jpg

Treated myself to a new jack as well. Upgraded from this......
http://i47.photobucket.com/albums/f176/Astra131/100_1636.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1635.jpg

To this bad boy. Got new axle stands as well and wheel chocks as well tobe on the safe side. The anorak in me really likes the fat front wheels.
http://i47.photobucket.com/albums/f176/Astra131/100_1638.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1637.jpg

Few pics after a good clean.
http://i47.photobucket.com/albums/f176/Astra131/100_1737.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1721.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1710.jpg

[Danny]

Forgot to add.

Fitted the Daewoo rear covers as well.

Before
http://i47.photobucket.com/albums/f176/Astra131/100_1706.jpg
After
http://i47.photobucket.com/albums/f176/Astra131/100_1707.jpg

[GazJevs84]

Lookin good bud

[Danny]

Cheers dude.

[braders]

looking good there Danny. All i can say is if your arches were catching the other day just check it hasnt rubbed the paint off the inside lip of the arch. If it has then it may soon rust and it only takes a small brake in the paint to let moisture it. Wouldnt want tin worm to start setting back in so soon.
Keep up the good work.

[Danny]

Cheers Braders.

I'll definitely get the arches rolled in the new year.

[braders]

I done the same i tried some 17s on mine of a mates car (stupid idea) ages ago. Anyway were the wrong offset and when i drove the car they catched slightly. Anyway didnt touch the lip in and then a while later the lip started to show signs of rust i painted it again before it got worse. Anyway there fine now so its worth checking sooner rather than later.

[mick g]

Be careful rolling the arches now they are in and painted mate, you may disturb the filler on the wing:thumbsup: Its looking great now with all the bits you have done to it:thumbsup:

[Danny]

Did a bit more work at the weekend so thought I had better update my thread.

On the way back from Westerham the other week the exhaust started blowing.
It turned out the centre section had broken off near the backbox.
Now check this. A local exhaust place said they would supply and fit the centre section for £95.

I only inquired out of interest and planned to do it myself anyway.

I bought the centre section from a local motor factors for £54.19.
The two rubber hangers were 75p each and I bought a couple for the backbox which were also 75p each.
A gasket was £2.20 and gasket putty £1.02.
Grand total £58.91. Can't beat DIY mechanics. :thumbsup:

After unhooking the backbox I had to get the piece of centre section out of it where it had broken off.
I'd sprayed it with a liberal dose of WD40 the night before to make my life easier.
There's a slit either side of my Janspeed 'zorst to make mating it up to the centre section simpler.
I decided to cut down this split then fold the metal inwards and pull it out with a pair of grips. It worked.
http://i47.photobucket.com/albums/f176/Astra131/100_1898.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1899.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_1900.jpg

Got a mate to help fit the centre section. It was either an awkward job on my own or straight forward with help.

After undoing the three bolts at the flange.
http://i47.photobucket.com/albums/f176/Astra131/100_1915.jpg

It was a simple case of lining up the new section. (pictured with rubbers etc)
http://i47.photobucket.com/albums/f176/Astra131/100_1905.jpg
The motor factors also supplied three small springs just in case it was a different flange fitting but I didn't need them so they are in the spares box.

After fitting the new rubbers I found the centre section vibrated against the floorpan. Cured this by putting the old rubbers back on, which were not that bad anyway gave the exhausr a bit more give.

Old centre section. Note slightly different design.
http://i47.photobucket.com/albums/f176/Astra131/100_1914.jpg


Unfortunately my mate accidentally pulled the handle off the jack while it was propping the Astra up, which made the jacking mechanism flick back into place.
This meant we couldn't get the handle back in because there was not enough room to insert it again.
http://i47.photobucket.com/albums/f176/Astra131/100_1917.jpg
We ended up using my 2 ton jack (in red pictured above) to lift the car further so we could get the handle back in and the heavier three ton jack back under the Astra.
Fun and games, eh? Watching a car you have spent about £3,000 on wobbling around on axle stands. :o

Anyway, after replacing the centre section and making sure the backbox was level we checked to make sure there was no exhaust leaks, which there wasn't.
Getting the backbox level was easy and makes me wonder why I have seen so many GTE 16v twin tailpipes fitted lop sided. :confused:
http://i47.photobucket.com/albums/f176/Astra131/100_1922.jpg

While the backbox was off I gave it a good clean.
For this I used some oil and a small sponge to loosen the dirt.
http://i47.photobucket.com/albums/f176/Astra131/100_1911.jpg
Then some Autoglym metal polish, a terry towel and elbow grease.
http://i47.photobucket.com/albums/f176/Astra131/100_1912.jpg
Before
http://i47.photobucket.com/albums/f176/Astra131/100_1907.jpg
After
http://i47.photobucket.com/albums/f176/Astra131/100_1913.jpg

My mate also gave me this bling air filter for free. Its a Simota and gives a slightly deeper induction roar. Possibly not to everyone's taste, but I like it.
Goes well with the rusty engine bay don't you think?
http://i47.photobucket.com/albums/f176/Astra131/100_1919.jpg

I also replaced the offside headlight with a spare I had as the old one (pictured) was leaking.
http://i47.photobucket.com/albums/f176/Astra131/100_1927.jpg
Interestingly the offside headlight is a Carello and the nearside a Cibie.
DarrenH noticed this at the last Westerham meet and was the same on his Astra 16v. Anyone know why they are not the same make?

Went round to see my dad that evening. He came home after I had parked on his drive. Unfortunately his wing mirror is broken on his van and he nearly reversed into the Astra. (shock) But luckily he, just, missed it.
http://i47.photobucket.com/albums/f176/Astra131/100_1943.jpg

My Astra GTE 16v.
http://i47.photobucket.com/albums/f176/Astra131/100_1944.jpg

Next main job is to get the leaking nearside footwell sorted. Hoping to crack on and get it looking good for Billing. :thumbsup:

[Addz]

JESUS! He is parked close! Surely they must have touched?

[DarrenH]

nice job danny :) that old centre section is aftermarket, maybe janspeed do you know ?

too late now but genuine GM gte16v centre section is only 31 quid trade club

i was down vauxhall today actually about my headlight, a new one was only gonna be 35 quid but its NLS ! it would have been carello again. i dunno about you but comparatively the cibie one looks way better quality and finish than the carello. bit of a coincidence we both ended up with carello on the drivers side, and both are rusting the reflector round the side light holder.

i popped down to partco and have a lucas unit on order which is 21 quid !!!

[GazJevs84]

Looking good mate

[Danny]

Thanks for the comments.

I think the exhaust was possibly a Janspeed item Darren.
TBH it's a bit of a mix and match affair although the manifold looks a good bit of kit.

I find the different headlights intriguing and agree the Cibie looks the better of the two.

My spare one will be sealed properly, don't know how yet, so it can be used again.

[Danny]

JESUS! He is parked close! Surely they must have touched?

Surprisingly they didn't Addz, but it was VERY close.

[DarrenH]

picked up a new headlight yesterday from motorparts direct (on the eurolink, new bit down by the stadium) its a lucus item (yum yum quality) and cost 21 quid!!!! i was so pleased at the quality i ordered a passenger side to match !!

[Danny]

Nice one Darren.

I'll bear them in mind if I need any bits.
Good price too.

[Danny]

Quick update regarding a bit of general maintenance and change of wheels.

Firstly, I bought these bucket seats from Brett (top man BTW) a couple of weeks ago for £50.
They've got a couple of little rips which I knew about before buying them.
I know a fella who could probably recover them for mates rates so it's all good.

Just need some sub-frames and give them a good clean.
http://i47.photobucket.com/albums/f176/Astra131/100_2148.jpg

I drove from Kent to Bristol to get the seats to give the Astra a good run as it doesn't get used much.

Although it was fine during the 370 mile trip, the engine management light has been coming on intermittently.

Ian T kindly pluggged it in to his Tech1 the other week at Westerham which flagged up the Hall sensor.
This is the plug that goes into the distributor and iirc monitors the ignition timing.

After a chat with a local engine diagnostic company (Bourne Performance 01795 437111) they recommended fitting a new distributor.
This cost £150 from a local motor factors (Ajays 01795 471737).

It was a straight swap and well easy. I reused the old rubber O ring because the new one was a very tight fit.

Also bought Tony K's (Another top man BTW) old gte wheels which were in superb condition and only cost £55 with V good tyres.
Already have a set of GTE rims, but they need a refurb and I could never make them as good as Tony's for less money.

Piccies.
New dizzy.
http://i47.photobucket.com/albums/f176/Astra131/100_2187.jpg

Wheels. These replaced the Vectra CDX rims already on the Astra which I'm keeping for the mo.
http://i47.photobucket.com/albums/f176/Astra131/100_2189.jpg

This is the car when I bought it.
http://i47.photobucket.com/albums/f176/Astra131/100_0009-1.jpg

After extensive bodywork, sills, arches, welding to floor, new passenger A post etc.....
http://i47.photobucket.com/albums/f176/Astra131/100_2190.jpg

And with GTE rims.
http://i47.photobucket.com/albums/f176/Astra131/100_2191.jpg

I really like the new wheels and plan to keep the car loooking standard until it gets caged up ready for track days some time later this year.

Thanks for looking. :thumbsup:

[DarrenH]

looking good mcfly !!!!

good to know we can still get recon distributors, thats if my supply runs out (got 2 spares lol)

what you gonna do with the tigra alloys ??

[johnl]

Looks good. I know what mine would look like with standard wheels now :) What side repeaters have you fitted on it?

[Danny]

looking good mcfly !!!!

good to know we can still get recon distributors, thats if my supply runs out (got 2 spares lol)

what you gonna do with the tigra alloys ??

Ha ha. Yeah its getting there Doc.

I'm gonna keep the CDX alloys for now as they will probably go back on when the cage and buckets are fitted.

I can't remember what make the side repeaters are. I bought them from a local car shop. I'll find out.

[G.TERI.E]

them gte rims are in very good condition, looking very nice Danny:thumbsup:

[richie00boy]

Does look well on the GTE wheels.

[Paulwoo]

I'm with the majority here, those wheels set the car off m8. Get the GTE sideskirts back on :) Would look the ticket.

[Danny]

Thank you for the kind comments.

Although it's nothing radical, it's taken a lot of money and time to get to the car to this stage.

Needs a bit more tidying, but is coming along.


I'm with the majority here, those wheels set the car off m8. Get the GTE sideskirts back on :) Would look the ticket.

The skirts were taken off when I had the bodywork done and will not be going back on as they are a water trap IMHO.

[Danny]

Little update.

Bought a roll cage off a member on here who had taken it out of his 8v GTE he was using for track days. (Sorry, I cannot remember his username)

The guy has now got a 205GTi for sprints as the Astra, surprise, surprise, had a serious problem with tinworm.

The cage is an OMP item and fits without cutting the dash.

Here's the cage.
http://i47.photobucket.com/albums/f176/Astra131/100_2200.jpg

I decided to wrap it as cheaply as I could while it is tucked away prior to fitting. After buying five rolls of clingfilm for 44p each (didn't use them all, rest are in my kitchen :) ) I covered the cage and then wrapped insulation tape around it which I nicked off my Dad.

http://i47.photobucket.com/albums/f176/Astra131/042608160916.jpg

The wrapping will keep dust, crap, paint off the cage while it's in storage.

With the price of petrol going up at an alarming rate running two cars is expensive, causing the project to run a lot slower.
However, through doing stuff myself and roping in a few mates the car will eventually be the track day weapon I want it to be.

Thanks for looking.
Some great projects on here BTW. :thumbsup:

[DarrenH]

nice update!

you know the best way to keep momentum in a project car? make it your daily driver!! otherwise theres no dealdines and its just slips and slips.

[Danny]

nice update!

you know the best way to keep momentum in a project car? make it your daily driver!! otherwise theres no dealdines and its just slips and slips.

Thanks Darren.

However I've been there with the daily driver/project back in the day with my modified Ford Onion and it was a total ball ache.

The Astra's just what I want. A car I can play with yet don't need for the daily commute.

Believe me, the motivation is there, money and time dictates when I get to use it!

How's yours coming along Mr H?

[Danny]

I was off work last week and had a bit of time to do a few jobs.

First one was to put some new adhesive on the back of the offside side repeater because it is letting in condensation.

http://i47.photobucket.com/albums/f176/Astra131/100_2321.jpg

Used this to stick on the back.
http://i47.photobucket.com/albums/f176/Astra131/100_2324.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_2325.jpg

It's still a little misty but hopefully will dry out.

Next job was to sort the horrendous leak in the passenger footwell which is ruining the inside of my car.
http://i47.photobucket.com/albums/f176/Astra131/100_2326.jpg

After taking the wing off I discovered a hole in the grommet which the indicator wiring runs through, so I plugged it with seam sealer.
Thank you to Ian T for advising me on this problem.
http://i47.photobucket.com/albums/f176/Astra131/100_2334.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_2338.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_2342.jpg

At PVS Astrayorkie and I checked for the dreaded bulkhead cracking problem and discovered it had indeed cracked due to movement in the metal and power steering rack.
Astrayorkie looked worried, but not as much as me cos I had to drive the thing home!
Anyway it got back with no probs. Hopefully a solution has come in the form of a mate whose dad has a garage. Work should start this weekend as I want it sorted for Billing.

My daily runner the mighty Metro also received some attention because the MOT was due. I know it is not a vox but thought it would be of interest.

All it failed on was three tyres and the rear brakes.
Three Firestone tyres cost £144.

After hammering the rear drums off I discovered one of the cylinders was leaking.
I had never done rear drums before so this was a good learning curve for me.
I decided to replace the shoes and both cylinders which cost £26.
TBH it was pretty straight forward and very satisfying doing it myself (oooer)
My neighbour's a mechanic and helped me bleed the brakes.
And that was it, job done.

Went back for the MOT re-test today and it passed. :thumbsup:

Piccies
The Astra's normally on axle stands, so the Metro fancied joining in.
http://i47.photobucket.com/albums/f176/Astra131/100_2349.jpg
Leaking cylinder. They cost £6 each,
http://i47.photobucket.com/albums/f176/Astra131/100_2350.jpg
This clip helps hold the cylinder in place and was a bit of a pain in the arse to fix in place.
http://i47.photobucket.com/albums/f176/Astra131/100_2354.jpg
The old pad (on the left) had more pad coverage than the new one. Interesting or budgeting?
http://i47.photobucket.com/albums/f176/Astra131/100_2356.jpg
This what rear shoes look like on a 1.1 Metro.
http://i47.photobucket.com/albums/f176/Astra131/100_2362.jpg
Danny's tip of the day. Whenever you do a job like this, lay the bits out as they come off so you know how they go back on.
http://i47.photobucket.com/albums/f176/Astra131/100_2363.jpg

At the last MOT I got an advisory cos the nearside rear arch was rusting into the sill. Got a bit carried away and had the rear arches done.
To save time and money I took the rear bumper off before taking it to the bodyshop. I did this at 6am in the morning before going to work!
Driver's side before.
http://i47.photobucket.com/albums/f176/Astra131/100_2318.jpg
After
http://i47.photobucket.com/albums/f176/Astra131/100_2346.jpg
Nearside before
http://i47.photobucket.com/albums/f176/Astra131/100_2319.jpg
After
http://i47.photobucket.com/albums/f176/Astra131/100_2347.jpg
This is the nearside where it was rusting into the sill.
http://i47.photobucket.com/albums/f176/Astra131/100_2320.jpg
After
http://i47.photobucket.com/albums/f176/Astra131/100_2348.jpg

Also treated myself to an Allen key set
http://i47.photobucket.com/albums/f176/Astra131/100_2345.jpg

And there you go. Some fantasic work going on in this section BTW which is giving me inspiration.

[DarrenH]

tip top matey !!!

is the wing still off the astra ??? its WELL worth sorting out that rust on the bumper mount bracket while you have access, wire wheel on a drill, or flap wheels and liberal slosh of hammerite will sort it

[James C]

The front of the inner arch looks like its only going to get worse. You should treat that rusty section while you have the wing off mate. Hopefully its just surface rust and wire wool and elbow grease is all that is required. Plus a bit of primer and paint.

Shame about the bulkhead. Hopefully it'll get sorted ASAP so you can get it to Billing this year.

Is it going to be done with the engine out? TBH i'm not sure if there is clearance behind the XE to repair without it out. My Dad had a MK2 Cav 1.8 and that had the bulkhead repair done with engine still in situe and it was never the same by all accounts.

Stop spending money on that noddy car too! Save it for the Astra. :wasntme:

[G.TERI.E]

danny it looks like theres a gromet missing from the A post where the loom wire's come out of and leads into the pass door, that may also be worth sorting, it should look like this one

http://i184.photobucket.com/albums/x299/gte786/08052008154-1.jpg

or fill it with seam sealer.

[Danny]

Thank you G.terie. I will investigate. :thumbsup:

Don't worry James it was just a tidy up cos I plan to hold onto the Metro as it is so cheap to run, plus I have always looked after my cars.

Things are progressing with bulkhead issue. Will keep you all updated.

Thank for looking.

[astrayorkie]

good man !!! keep at it

[richie00boy]

Did you get the Metro done at the same place as the Astra? Did you tell them to do it right or just a quick job?

[Ian T]

I'd seal all of these bits while it's apart...

http://img99.imageshack.us/img99/3052/1002334op0.jpg

The scuttle drain is a subtle one, where the water seeps in between the panels and causes brown mayhem.

The door hinges seem to suck up water too, so if they're not already well sealed, get at them!

Obviously the grommet should be there, is it simply pushed inside?

Ian.

[DarrenH]

another potential leak is the headlight washer jet resevoir bracket (bit of a mouthful)

the 2 bolts and rail directly below the side repeater grommet, which is also directly below the scuttle drain and perfectly angled to channel water into the threads down the back of the bracket

i'd take them both out, bracket off and fill holes.

[Danny]

Did you get the Metro done at the same place as the Astra? Did you tell them to do it right or just a quick job?

Yup, same place as the Astra.

Proper job Mr Richie. New panels and both sides sprayed so it all matches.

[Danny]

Thank you for all the advice. Much appreciated. :thumbsup:

Due to not having that much time to get it ready for Billing I'm not sure if I can get all the engine bay done in one hit.

This would be ideal obviously, but this project is being done on a budget and things are done as and when I can afford them.

Most likely scenario is the bulkhead will be sorted and the other stuff over winter.

I'm going on holiday to Australia (Perth) in August so need to save for this, hence not doing the full monty to the Astra just yet.

It will all be done eventually, but these things do not happen overnight.

[DarrenH]

i'm also gonna attempt to tackle the bulkhead soon also. hopefully we can collaborate experience!!

[Danny]

i'm also gonna attempt to tackle the bulkhead soon also. hopefully we can collaborate experience!!

I'm sure we will Darren. :thumbsup: If I can help at all, you know my number.

A mechanic mate of mine said he can sort the bulkhead with work due to start this Saturday. (June 28)

I've stripped out the carpet in the footwells, passenger seat and part of the centre console and bought some underbody seal to slap over the welds.

Gonna use an old Mk2 wing to patch up the bulkhead as I had it spare, so no point in paying for metal.
I know it means cutting up a perfectly good wing, but I can get another if need be and for the moment keeps costs down.

Also bought some power steering fluid for when/if the rack has to come off.

I also printed off some of the bulkhead pics from TomGTE's diary as reference.
VERY helpful. Thank you.

I was supposed to be going away on a stag do next weekend but cannot get the time off work, however, it means I have more time to sort the Astra, which I could with TBH.

My mate guarantees me it will be ready for Billing. I bloody hope so cos I wanna go for the full weekend and have already paid. Last year rocked!

(BTW, thanks to JamesC for a lift there and Ronin for a lift back last year. Hopefully this time I will make it under my own steam!)

[Danny]

Little update.

Good news, my mate managed to do a temporary fix on the bulkhead which means the Astra is going to Billing. :bananajump: :bananajump: :bananajump:

Sorry for the poor quality of some of the welding pics but we didn't have much time.

Underseal on the offside arch scraped away ready for temporary repair.
http://i47.photobucket.com/albums/f176/Astra131/100_2538.jpg

My mate welding the old girl.
http://i47.photobucket.com/albums/f176/Astra131/100_2543.jpg

Nearly there.
http://i47.photobucket.com/albums/f176/Astra131/100_2540.jpg

Done with a load of underseal slapped over it.
http://i47.photobucket.com/albums/f176/Astra131/100_2546.jpg

While the wheel was off we noticed the brake pads needed changing so I did this when I got home. As you can see they were pretty low.
http://i47.photobucket.com/albums/f176/Astra131/100_2549.jpg

The following day I bought some Meguiars hot tire shine spray as recommended by Tony K. (Top man BTW)
And a Meguiars clay kit. Unfortunately rain is forecast for the weekend, so I'll see how it goes.
http://i47.photobucket.com/albums/f176/Astra131/100_2552.jpg

That's all for now folks. See you at Billing. :thumbsup:

[DarrenH]

mines torn down that seam too, very recently. i was gonna run a seam of weld along the crack too, but it would be p-ssing in the wind compared to what i found around the rack mount, with a lead light, the other day.

oh well !

[5 door sx 2.0l xe]

mine split there too and a hole apperd so i had too plate mine up

[Danny]

Yes unfortunately it is a common Mk2 problem.

I'm just keeping my fingers crossed the temporary repair holds so I can take it to Billing.

[Tony K]

The following day I bought some Meguiars hot tire shine spray as recommended by Tony K. (Top man BTW)
And a Meguiars clay kit. Unfortunately rain is forecast for the weekend, so I'll see how it goes.
http://i47.photobucket.com/albums/f176/Astra131/100_2552.jpg



Don't forget the before and after pictures.

[Danny]

Bit more done and quite a few pics to chart the progress.

They appear in the order the work was done.

Due to the threat of rain the other weekend I was lucky enough to get the Astra to my mate's yard so I could use the Meguiars smooth surface clay kit I had bought. As it was, the rain never materialised.

Here it is after not being washed for three weeks.
http://i47.photobucket.com/albums/f176/Astra131/100_2559.jpg

Here it after being washed with Autoglym shampoo and some Meguiars Hot Tire Shine spray added.
http://i47.photobucket.com/albums/f176/Astra131/100_2562.jpg

The clay, which you knead first to make it pliable, works by spraying a chemical on the bodywork first and then wiping the clay over the bodywork.
Pic of the clay
http://i47.photobucket.com/albums/f176/Astra131/100_2567.jpg

The car was only sprayed in October last year so it wasn't too bad, but the clay still made the bodywork smoother and was great for getting the bugs off the front.
Difficult to see in these pics, but definitely made a difference and I recommend it.
http://i47.photobucket.com/albums/f176/Astra131/100_2573.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_2570.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_2574.jpg

All lovely and shiny.
http://i47.photobucket.com/albums/f176/Astra131/100_2578.jpg

Alas my joy was soon given a kick in the knackers after putting together the interior.
This was stripped out prior to my mate welding the bulkhead so the front carpet did not catch light. Welding is temporarily done BTW. Rest will be done soon.
http://i47.photobucket.com/albums/f176/Astra131/100_2588.jpg

As usual I cannot do a job on the Astra without finding another million more.
Feeling rot, rot, rot. My finger is touching the sound deadening.
http://i47.photobucket.com/albums/f176/Astra131/100_2580.jpg

Dustpan and rust.
The floor was covered in little bits of rust and a small pool of water where it is leaking slightly still from the wing.
A few good dollops of seam sealer will sort this. Thanks to Ian T and Darren for help in where to seal. Will do this soon.
Pool made worse 'cos it was raining.
http://i47.photobucket.com/albums/f176/Astra131/100_2584.jpg

While I'm putting it together I had a quick look to see why this heater lever had lost tension.
http://i47.photobucket.com/albums/f176/Astra131/100_2587.jpg

This is why. Part of the mechanism had dropped out this slot. My good friend Mr cable tie sorted this one.
http://i47.photobucket.com/albums/f176/Astra131/100_2585.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_2586.jpg

For those that don't know, here is where the screws are located that fix the 16v centre console in place. Once undone pull the console towards the back of the car to release it from two pins on the floorpan near the bulkhead.
http://i47.photobucket.com/albums/f176/Astra131/100_2594.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_2592.jpg
Two 8mm bolts need to be undone here as well.
http://i47.photobucket.com/albums/f176/Astra131/100_2596.jpg

All back together, hoovered and dash cleaned.
http://i47.photobucket.com/albums/f176/Astra131/100_2598.jpg

Did a couple of last minute Billing tidy up jobs on Wednesday.
Sprayed wipers. Bit a bodge job TBH, but they'll do for now.
http://i47.photobucket.com/albums/f176/Astra131/100_2599.jpg

And fitted the towing eye cover half (in the bloody rain!) 'cos the old one broke.
http://i47.photobucket.com/albums/f176/Astra131/100_2601.jpg

And finally some idiot frantically trying to get his Astra ready for Billing. (That'll be me then.)
http://i47.photobucket.com/albums/f176/Astra131/100_2591.jpg

[Ian T]

You'd have laughed if you'd seen me today.

Outside the car is lovely, largely thanks to Brian (beegee) who took pity on me rushing around the last couple of weeks and popped down to lend a hand. :)

Ian.

[Danny]

Laugh!

I'd have bloody helped you as I know what a chore it has been getting the Astra ready.

Glad to hear Brian helped.

You have PM BTW.

[beegee]

I don't know what your smiling about, look behind you, some sign-so nick the steering wheel . lol .
ps. and two seats. :rolleyes:

[Tony K]

Liking the claying results, doing mine again today so we'll have a closer inspection and compare over the W/E.

Top stuff!

[astravanmk2]

Looks good Danny,
I'm franticly trying to get mine hoovered out but it wont stop raining lol

It will be the coin op vac at billing BP at this rate lol

[DarrenH]

paintwork looks awesome danny

darren (sick of the site of rusty footwells)

[Tibs]

Looking good, i'll be sure to get some pictures of it this wk end mate.

[Danny]

Thanks for comments.

I know what you mean Darren. I'm fed up seeing rust but must keep at it 'cos I can see there's potential now.

[Ian T]

Stick at it Danny - you've got a lovely car and we've got some collective experience on how to sort the bulkhead issue with several different options for you to consider depending what you want it to look like.

Good to see it looking well loved at Billing too, hopefully you didn't notice mine with mud up the side!

Ian.

[Danny]

Time for an update.

As mentioned in the spotted thread started by Mr K the head gasket went on the Astra on Friday. (August 29)

The AA confirmed it was the head gasket. I knew it was leaking water and was gonna check it out next weekend.

Plan is to get my dad's neighbour, who is a mechanic and has a garage, to check it out.
Hopefully it's just the gasket. If it isn't then I'm going to buy another XE as it will be cheaper than getting the head skimmed.
Tempted to turbo it as that's always been the aim but as I'm looking into buying a house it's a no go at the mo.

The bulkhead also needs welding. Ian T and Darren have kindly offered to help fix it which I really REALLY appreciate. (You're both absolute legends, thank you) :thumbsup:

So, over the next few months it will all be sorted, but beforehand I need to find somewhere to live in Peterborough because I've got a new job.

I'm gonna be a features writer for AM. This stands for Automotive Management and is a magazine aimed at car dealers.
Writing about cars has always been my ambition hence the sacrifice of moving.
It's gonna be difficult moving away from my family and friends but that's the way it is.

Piccy time.
After discovering chocolate milkshake in my expansion bottle.
http://i47.photobucket.com/albums/f176/Astra131/PICT0250-1.jpg
I came home on this.
http://i47.photobucket.com/albums/f176/Astra131/PICT0253.jpg
The Astra was taken to my Dad's where it will stay until the work is sorted.
http://i47.photobucket.com/albums/f176/Astra131/PICT0265.jpg

While I was at my parents' house my mum's friend came round in his 4 litre TVR Tuscan. Some pics.
http://i47.photobucket.com/albums/f176/Astra131/PICT0260.jpg
http://i47.photobucket.com/albums/f176/Astra131/PICT0258.jpg
http://i47.photobucket.com/albums/f176/Astra131/PICT0257.jpg
http://i47.photobucket.com/albums/f176/Astra131/PICT0256.jpg

He said the only problem he has had was after he accidentally kicked the fusebox because it is fitted right above the pedals!
http://i47.photobucket.com/albums/f176/Astra131/PICT0261.jpg

To open the door from the outside you press this button nder the wing mirror.
http://i47.photobucket.com/albums/f176/Astra131/PICT0263.jpg
To open the door from the inside there are buttons either side of the stereo.
Left is passenger side right is driver's side.
http://i47.photobucket.com/albums/f176/Astra131/PICT0262.jpg

[jimbojetset]

TVR looks good but keep doing the Astra.

[Ian T]

Couldn't you have agreed a swap Danny? :(

Good to see you today and I'm sure it's not going to be too hard to fix your baby.

Ian.

[Danny]

As much as I love the Astra, that TVR looked very tempting.

Ian.
I think it all sounds a bit worse than it is and WILL be fixed.
The car's 70 per cent complete now so I'm not going to give up plus with plans to buy a house, that means a garage is on the way for the Astra.

[Mr-G]

Its an easy fix matey, like you say if its the gasket then its a pretty basic job, like i said at the meet, if the head has gone porus you can get it fixed for about £70 these days and it will never go porus again ;)

[DarrenH]

dont be scared by a head skim, its 30-40 quid kind of action if delivered stripped and ready to reputable machine shop. i'd rather have a gasket skim than buy another entire engine of unkown quantity.

obviusly something that needs to assessed on the fly

[Danny]

Mmmmm some good responses there and thanks for the words of wisdom.

Looks like it won't be another engine after all.

I'll let you know how I get on.

Many thanks for the support. That's what makes this club great. :thumbsup:

[Danny]

Quick update.

Planning for my move to Peterborough has taken a lot of my time recently what with saying goodbye to friends, packing etc, hence why I have been quiet of late.

Fortunately though, the Astra's blown head gasket is sorted.

Would have loved to of sorted a lot of this myself with help from people on the site but due to time constraints it was a no go.

Anyway, only the head gasket needed replacing due to the old one perishing.
My dad's neighbour (who did the work and is a mechanic) said he thinks the head has been skimmed anyway, so I was lucky no more had to come off.
He also replaced the cambelt, camshaft oil seal, crankshaft oil seal and gaskets on the inlet manifold and exhaust manifold.
A new thermostat was also fitted as the old one was knackered.

He took it out for a run and said everything was fine. :Banane44:

Just the bulkhead to weld, tidy the bodywork round the engine bay and spray the front bumper and she'll be tip top.
Really wanna get her looking nice for Billing 09

Few pics of work in progress.

http://i47.photobucket.com/albums/f176/Astra131/092808161202.jpg
http://i47.photobucket.com/albums/f176/Astra131/092808161143.jpg

I really feel as though progress is being made now. TBH it's people like Brett, Harvey etc who are building projects on a drive that really inspires me.

[astramad]

theres nothing like working on the drive in the winter cold wet but still having fun doing your car im looking forward to another winter of do that to lol

[richie00boy]

Good luck with the new job Danny, sounds like a good move for you. At least you will have Tony in the area to natter with and help each other out. Shame you didn't move here though!

[beegee]

Glad to see its wasn't such a disaster engine wise.

Wishing you all the best in the new job, be seeing you on top gear yet. You could replace the Hamster. I know what! We could call you the Ferret. More kick ass attitude than a hamster.

[Danny]

Cheers Richie.

Roughly how far is Peterborough from you?

That's the good thing about a website based club, if you move there will usually be people you know.

Definitely gonna pop round Mr K's for a cuppa. I think Screamer 69's in Peterborough too so that's good.

I know what you mean AstraMad. I've never had a garage to work on my Astra yet keep going. It's called being hardcore, enthusiastic, stupid or something like that.

[richie00boy]

Unfortunately Peterborough is 3+ hours each way. Much too far.

With your bodywork pretty much sorted you are on the home run now. I think I'm going to take a leaf out of your book and get a little runaround, that will alleviate 90% of the problems I've got trying to do mine, not to mention the lack of wear and tear when it finally is done.

[Danny]

Fair distance then, but still bear me in mind if you are desperate.

In six months I will be able to get test cars as part of my new job, so a three hour run in something quite tasty (hopefully) sounds good to me.

Getting a cheap runabout is not as expensive as you might think.
The Mighty Metro's insurance is only £20 a month full com and I do all the servicing myself.

It only cost me £450 plus I don't have to worry about where I leave it, unlike the Astra.

You could easily do the same Rich.

[Tony K]

Peterborough has been readied for his arrival.

http://dvice.com/pics/_Craftsman-1470-pc-Professional-Tool-Set.jpg

[Danny]

Ha Ha.

Very funny Mr K.

TBH, it's a 19-year-old Vauxhall, so I could do with ALL those tools.

Just to let you all know, the Astra's blown head gasket has now been fixed along with oil leaks on the crankshaft seal and camshaft seal.
The head didn't need skimming, although the mechanic who did the work said it's possibly been skimmed at some point.

A new thermostat has also sorted a problem with the car cutting out in traffic.

The mechanic who did it said she now runs fine. :Banane44:

Just need to get the bulkhead sorted now and she'll be tip top.

Sorry, no pictures as I've been moving to another part of the country.

BTW Mr K milk, one sugar please. ;)

[Danny]

The astra was up for its MoT a couple of weeks ago which turned into a bit of a saga, but came good in the end.

I'll keep this as brief as I can.

Right, it failed on:
Number plate bulb
Rear stop lights not working
Rear fog light not working
Offside front lower suspension joint
offside front brake pipe
broken exhaust rubber on centre section
nearside front side repeater not working
handbrake inefficient
Horn not working
Excessive carbon monoxide

The MoT bod also said there was excessive play in the steering column and said it was the upper bearing.
I bought another column from a breaker's and an upper bearing replacement kit from Vauxhall (which still hasn't arrived after two weeks).

However, when my mate and I looked at the bearing on the car we couldn't see any problem.

I presumed the boss wasn't snug enough on the column so hammered it on a bit more. I didn't say anything to the MoT dude and he passed it.

The horn not working was because I have the wrong fitting for it after buying a snap off steering wheel.
It's something I have just never got round to sorting so my mate wired a temporary one in which is operated via a red button on the dash.

After several phone calls, a 25 mile round trip to get the column and some help from Mr K showing me where to buy various bits (thanks Mr K, I love you) my mate and I set to work fixing what failed.

And what a bloody mission that was. It friggin rained all day, we used up three torches after it got dark at 4pm and then the Astra's battery died.

This wouldn't have been that bad but it was blocking the Metro and we were both going to a party that night.

After swapping batteries we were off, only to get an earful from my mate's girlfriend for being late back to his!

Anyway, we got it all done and it's now got a year's ticket and another six months' tax.

Prior to the MoT I noticed it was quite juicy. Like 198 miles on one tank juicy. (shock)

I discovered this was because a fuel pipe was leaking. I couldn't have it leaking fuel everywhere so called the AA who replaced the pipe.

Piccy time
Poxy rain.
http://i47.photobucket.com/albums/f176/Astra131/PICT0383.jpg

My new horn
http://i47.photobucket.com/albums/f176/Astra131/PICT0396.jpg

Bought a Dremel as well. Really handy tool.
http://i47.photobucket.com/albums/f176/Astra131/PICT0405.jpg

After all this work the Astra needed a wash.
Forget Autoglym and Meguiars, what you need is a five-year-old niece.
Here's mine. I did help, honest.
http://i47.photobucket.com/albums/f176/Astra131/100_2712.jpg
http://i47.photobucket.com/albums/f176/Astra131/100_2711.jpg

After washing the car it got stuck in my Dad's garden and I ended up spraying mud all over it. :duh:
http://i47.photobucket.com/albums/f176/Astra131/100_2716.jpg

Anyway, it's all sorted now and the Astra's tucked up for the winter.

It's at this point I must praise the mighty Metro. This car has been a Godsend, it's cheap to run and easy to maintain.
I've decided not to sell it, instead I will give it to my parents.
We get cars on test at my new job, so chances are I won't need it next year.
http://i47.photobucket.com/albums/f176/Astra131/100_2719.jpg

Next job on the Astra is to weld the bulkhead and tidy the bodywork around the engine bay.

[Brett]

Ive just had the bearing go dry in my steering column, spent last saturday getting a new one and fitting it! Pain in the arse!!

Good to see the cars fixed though mate and the new job sounds awesome:)

[Danny]

Yeah, new job's great.

Bit tired at the mo, but will put a post up in general chat about it later this week.

I'm glad we didn't have to do the bearing cos it did look like a pain and feel pleased everything is sorted and it's off the road for the winter.

How long did the bearing take, Brett? Did you take the column out to do it?

[Danny]

Bought some new wheels for the Astra off one of the Max Power lads.

They're Wolfrace Street Octane alloys with Kumho 205/40 ZR17 tyres.

All the rubber has lots of tread and the rims are in good condition.
Got them for £100 which I thought was a pretty a good deal.

I need to get some spacers before I can fit them, hence this rather crude picture to give an idea how they will look.

They won't be fitted for a while as I want to get the engine bay tidied up and bulkhead welded first.

Beforehttp://i47.photobucket.com/albums/f176/Astra131/100_2753.jpg

After
http://i47.photobucket.com/albums/f176/Astra131/100_2754.jpg

Not gonna go for this, but thought it would be interesting to show what the car looks like with the exposed nut look.
http://i47.photobucket.com/albums/f176/Astra131/100_2752.jpg

[Gteman]

I do like the wheels Danny pity they aren't a straight fit though.

[Danny]

It is a bit of a pain, but shouldn't be a problem getting the spacers.

[F'astra 16v]

New wheels look great matey, love the capless look on the GTE wheels never ran caps on mine looked mint, lol.

[Danny]

Time for an update......

Despite the fact I haven't touched the Astra in nearly six months I've still been busy organising the next phase.

Plan is:
At the end of June strip the whole front end, body panels off, engine out etc.
Then low loader the car to my mate's who will weld the cracked bulkhead and tidy and spray the engine bay.

Unfortunately the car won't be done in time for Billing.

Preparing for this took four days:
I had to tidy up my dad's garage and then do four trips to the tip with the rubbish.

Sort all my spare car parts to work out which ones to sell to help fund the work.

Clear and sweep the drive.

All this and I hadn't even touched the Astra! Actually I did start it up cos it had been standing idle for six months. It started no probs. Wahey.

Piccies
Been collecting loads of containers to keep all the nuts and bolts in when the engine comes out.
http://i47.photobucket.com/albums/f176/Astra131/DSC00418.jpg

One minor point is the Astra's blocked in by all this earth at the mo.
It should be moved soon, if it isn't I will have to get busy with a shovel.
http://i47.photobucket.com/albums/f176/Astra131/DSC00127.jpg

Bit of fun........

My mate Amanda came round to "help" sort the garage.
I made her a cuppa and asked her to give me a hand and this was her response.
Charming!
http://i47.photobucket.com/albums/f176/Astra131/DSC00163.jpg

Here I am also "helping"

"Just give me a minute, Mand, and I'll be straight over to help you with that really heavy box"
http://i47.photobucket.com/albums/f176/Astra131/DSC00167.jpg

[Angieinpink]

A up mate, just read this thread for the 1st time.. sounds great car... but i cant access any piccies....:hissyfit:

[Danny]

Thanks Angie.

This is a bit odd.

I could see the pics last night.

Logged in earlier and couldn't see them, but now I can.

Maybe log out then log in again Angie.

[Danny]

Yup. Just checked and I can see the piccies.

[beegee]

That big pile of earth seems a bit drastic! Have you thought about fitting an alarm to immobilise the car?:D

[Angieinpink]

Yup. Just checked and I can see the piccies.

:hissyfit::hissyfit::hissyfit:

Must be me, can see you in the wheelbarrow, lol but none of the "old" piccies, is it because they were posted ages ago. Or do i have a $hite laptop??? :(

[Danny]

Lol Beegee.

The earth's to level the garden out.

If my dad's mate doesn't come round soon with his digger I'm gonna have to move it myself. Keeps you fit this car restoration stuff!

In fact, the car's alarmed, immobilised, has a snap off steering wheel, de-locked, door pins removed, covered by CCTV and has a big pile of earth in front of it.

Apart from nipping into town occasionally my mum's ALWAYS indoors.

Oh, and I've taken the battery off.

Hopefully it's not going anywhere. :thumbsup:

There was a guy selling windscreens off cheap on here the other week, so I bought one and picked it up at the weekend.

BIG, BIG thanks to JameC for texting me the measurments of his windscreen so I knew it would fit in the Metro. :thumbsup:
You're an absolute gent Mr James.

http://i47.photobucket.com/albums/f176/Astra131/DSC00334.jpg

[Danny]

The pics posted earlier in the thread cannnot be seen because they are old.

However the pics I posted at 11.35pm yesterday can be seen, Angie.

Does that help?

Good luck on your restoration BTW.

[Angieinpink]

The pics posted earlier in the thread cannnot be seen because they are old.

However the pics I posted at 11.35pm yesterday can be seen, Angie.

Does that help?

Good luck on your restoration BTW.


Ta hun for that...... thought that was the case...:thumbsup:

:thumbsup: Mark's picking the car up Mn 1st June, (280 mile round trip) and OMG i cant wait.... hopefully the poor guy if he's got time will do up dates for me/everyone.... appreciate the good wishes, its been a long time coming. sorry for mini thread steal..:thumbsup:

[Danny]

No worries, Angie.

Glad it's all coming along for you. Sounds like things are finally coming together.

[Angieinpink]

Ta, any chance you can put piccie up, for the lame arse's that didnt read the thread before the old piccies stopped working:love-smiley-028::applause:

[Danny]

Firstly, sorry to AngiePink for not posting the earlier pics up like I said.
Bear with me. I will do it.

Before tho, I need to do an update.

The bulk head has split on my GTE so instead of just having it welded I decided to strip the whole front end and tidy all the nasties.
A mate will be cleaning up all the rust and re-spraying the engine bay.

The rack was left in place so I could steer it onto the recovery truck and servo because one of the servo bolts rounded off. Both parts will be taken off so the work can be done.

The Money shot! As you can see, it looks like the bulkhead has been repaired before, but obviously it didn't last.
http://i47.photobucket.com/albums/f176/Astra131/DSC00561.jpg

Wider shot of the area.
http://i47.photobucket.com/albums/f176/Astra131/DSC00560.jpg

Other side of bulkhead.
http://i47.photobucket.com/albums/f176/Astra131/DSC00559.jpg

The stripping also unearthed split power steering bellows.
http://i47.photobucket.com/albums/f176/Astra131/DSC00543.jpg

Bye, bye GTE. Off to the welding hospital. :wave:
http://i47.photobucket.com/albums/f176/Astra131/DSC00574.jpg

Lots of pics of all the nasties.

http://i47.photobucket.com/albums/f176/Astra131/DSC00570.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC00558.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC00557.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC00573.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC00569.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC00563.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC00548.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC00547.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC00544.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC00542.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC00522.jpg

[Danny]

Ooops. Meant to add a caption to this pic. I couldn't undo these two bolts on the power steering pipes, so they stayed on for now.

http://i47.photobucket.com/albums/f176/Astra131/DSC00542.jpg

Right, I need to replace some parts.
I have an idea where to buy them from, but would appreciate recommendations from people on where they have bought these parts before so I know I'm using good companies.

Parts needed:

Three engine mounts
Both anti-roll bar bushes
New steering rack
New heater hoses, numbers 90572561 and 90410151
Bottom hose, number 90322127 (engine to radiator)

Thank you in advance for any advice offered. :thumbsup:

[Danny]

And new oil cooler pipes required.

[richie00boy]

That's pretty rotten, makes me feel a bit better about attempting mine lol.

Why do you need a new rack?

I would suggest Autovaux for the bits. However I bought the last remaining rear mount from Vauxhall by mistake a few years ago before I realised 16v ones were different to 8v ones. I'll bring it you to Billing if you are happy to pay what I bought it for - think it was £35 or £45.

[johnl]

Heater hose's are available from Vauxhall still, or they were last year. Cost about £9
each.

The bottom one however is not available from Vauxhall any more.

Engine mounts I believe some are still available at Vauxhall if not autovaux or your local motor factors.

Also after seeing the amount of rust in your engine bay makes me feel a whole lot better about the few bits I have on mine. Or did your's not look to bad till you started stripping it down?

[astrayorkie]

lots of work to do good luck with it all ...

you can never have enough security...lol

[DarrenH]

yikes, that does look bad, but atleast you are going full on proper job with the front end strip down, good job :D

mobile sand blast next ?

[laney]

bloody hell mate, have you been feeding the tin worm? looks like the bugger been feasting on your car, as others have already said, its better do do it all in one go, at least the engine is out of the way to make repairs easier, i would have the bay blasted, then at last you can see all the hidden rust, i had mine done by a mobile bloke, made a mess but my painter loved all the blast in corners etc, lol

[G.TERI.E]

:eek:!!!

looking at them pic's is a bit scarey,

glad to see your having it sorted.

[Danny]

Thank you for the comments.

What's even scarier is this car has an MOT. (shock)

I knew it was bad and is quite refreshing to know what's what.

Thank you also to the people who recommended where to get parts from.
It's reassuring when the same place is mentioned a few times.

Thank you also Richie, but I'll get all the mounts in one go. I appreciate the offer, though mate.

TBH this car was (is) rotten. But hey, I don't have x-ray vision and only paid £700 for it three years ago, plus I'll keep it forever.

Moral of the story, don't let me buy a car for you!

[Danny]

That's pretty rotten, makes me feel a bit better about attempting mine lol.

Why do you need a new rack?

I would suggest Autovaux for the bits. However I bought the last remaining rear mount from Vauxhall by mistake a few years ago before I realised 16v ones were different to 8v ones. I'll bring it you to Billing if you are happy to pay what I bought it for - think it was £35 or £45.

I need a new rack because the old one was leaking, Richie, and the bellows had split.

[James C]

More importantly Danny it does sub 15 sec 1/4s with the interior in.

Come to mention it, thats probably due to the weight savings in rust holes LOL.

Keep up the work mate.

Want to see it on the road again soon!!

[Danny]

More importantly Danny it does sub 15 sec 1/4s with the interior in.

Come to mention it, thats probably due to the weight savings in rust holes LOL.

Keep up the work mate.

Want to see it on the road again soon!!

Lol. Very true Mr C and a good reason for keeping it.

Don't worry, it will deffo be back. In fact I want Westerham to be its first proper outing. :thumbsup:

[Danny]

Progress!

This is where the Astra's been for the last few weeks.
My mate's just set set up his own bodywork business and agreed to do mine for mates rates.
I'll post up his full details next week.
http://i47.photobucket.com/albums/f176/Astra131/DSC00830.jpg

Here's some various pics of fixed bits and areas awaiting attention.
I took them on Wednesday this week. My mate phoned me today and said everything's done! Wahey.

He's also seam welded round the suspension turrets and down the chassis legs and will be spraying the engine bay early next week.

Big thank you to Astrayorkie for giving me the paint for the engine bay. Cheers fella.:thumbsup:

Bulk before.
http://i47.photobucket.com/albums/f176/Astra131/DSC00561.jpg

After
http://i47.photobucket.com/albums/f176/Astra131/DSC00823.jpg

http://i47.photobucket.com/albums/f176/Astra131/DSC00560.jpg

Nearside before
http://i47.photobucket.com/albums/f176/Astra131/DSC00559.jpg

After
http://i47.photobucket.com/albums/f176/Astra131/DSC00844.jpg

Random shots
http://i47.photobucket.com/albums/f176/Astra131/DSC00815.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC00816.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC00827.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC00828.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC00833.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC00835.jpg

Next on list:
Fit new suspension (Koni shocks and Eibach springs)
Refurbish rear beam and fit new polybushes all round.
Underseal underside of car.
Get front bumper resprayed.

[Danny]

Bulkhead after. Sorry, my 'puter's throwing a hissy fit with pics tonight so had to post it again.
http://i47.photobucket.com/albums/f176/Astra131/DSC00813.jpg

And what was (or was not) holding my car together.
http://i47.photobucket.com/albums/f176/Astra131/DSC00821.jpg

[screamer69]

nice to see some parts being done :)

[mick g]

Some good work done there Danny, your mate will be busy if thats the standard of work:thumbsup:

[James C]

Some good work done there Danny, your mate will be busy if thats the standard of work:thumbsup:

Indeed, where is this fella based Danny?

Does he have spraying capabilities?

Mine is shortly to go into hibernation where I will also treat and paint the underside then I want it blown over prior to being used again.

[Danny]

Thanks for the kind words.

TBH my mate's not done an apprenticeship and is self taught.

He's a VW nut at heart and built several bugs of his own plus had a hand in several projects.

Tony's been doing all this for about 15 years and loves it so much he decided to do it for a living.

I cannot thank him enough, there's just no way I could have afforded to pay a bodyshop to do all that work.

JamesC
I'll PM you Tony's details.

The best thing about him is there's nothing he won't tackle and no job is too difficult.
That's why I needed someone like him to do my Astra!

His full details will be posted next week as he's only just started and needs to sort a couple of things out.
I cannot recommend him enough to the good people on here. :thumbsup:

[Danny]

Actually, sod it, it'll be ok to put Tony's details up now.

His number is 07764 141 620

Also check out his website www.lustforrust.co.uk

He's based in Maidstone, Kent.

If you thought my Astra was rusty, look at Tony's Porsche 356 he's restoring on his website!

[richie00boy]

Does look like a cut above a lot of other Bodyshops Danny, good find.

[Danny]

Cheers Richie.

Yes I'm lucky to know Tony.

I knew him before he went into business so he's a good friend anyway.

I can't recommend him enough. :thumbsup:

[Danny]

The GTE's back!

Before I post lots of pics, here's a little piccy of my garage.
Oh yesh. After years of working outside in the wind and rain I finally have my own garage after buying a house.

I kitted it out the other day and am so pleased to finally have all my tools in one place rather than scattered between my home and parents' house.

Obviously I'm not gonna display the contents on a public forum but you get the idea.
Workbench, shelves, vice etc.

http://i47.photobucket.com/albums/f176/Astra131/DSC00897.jpg

And onto the Astra. All the rusty bits of the 'bay have now been sorted by my mate who owns www.lustforrust.co.uk

I would like to make it clear although the welding is spot on, there are some paint runs.
This is because I got what I paid for. My mate, Tony, can do show car finishes, but on this occasion I wanted it solid, not show. Most of the runs won't be seen anyway.

As you can see, Tony put a hell of a lot of work into my car and for the money (I'm not gonna say how much, so don't ask) it was an absolute bargain.

Piccy time.
Before
http://i47.photobucket.com/albums/f176/Astra131/DSC00547.jpg

After
http://i47.photobucket.com/albums/f176/Astra131/DSC00873.jpg

Before
http://i47.photobucket.com/albums/f176/Astra131/DSC00557.jpg

After
http://i47.photobucket.com/albums/f176/Astra131/DSC00857-1.jpg

Before
http://i47.photobucket.com/albums/f176/Astra131/DSC00827.jpg

After
http://i47.photobucket.com/albums/f176/Astra131/DSC00865.jpg

Before
http://i47.photobucket.com/albums/f176/Astra131/DSC00570.jpg

After
http://i47.photobucket.com/albums/f176/Astra131/DSC00860.jpg

Before
http://i47.photobucket.com/albums/f176/Astra131/DSC00560.jpg

After
http://i47.photobucket.com/albums/f176/Astra131/DSC00813.jpg

Before
http://i47.photobucket.com/albums/f176/Astra131/DSC00559.jpg

After
http://i47.photobucket.com/albums/f176/Astra131/DSC00844.jpg

The whole 'bay was also seam welded.
http://i47.photobucket.com/albums/f176/Astra131/DSC00868.jpg
This adds strength and also closes up areas which due to their lip type design can attract dirt and water thus encouraging rust, and I could do without anymore rust!

Due to buying a house it may take a few months to put back together, but it is one of my priorties.

I'm also doing a blog on the restoration on the Practical Classics' website where I managed to get a plug in for the Mk2 Club.

That's all for now folks. I'm really enjoying reading other people's diaries as well which gives me great inspiration.

[richie00boy]

Double good news and congratulations then!

Looking good, bet it feels nice to have it back.

[Danny]

Forgot to add.

Also popped over to see Cemex and bought a load of black interior parts.
BTW nice meeting you Cemex. :thumbsup: I highly recommend him if you do need parts as he's a good bloke.
http://i47.photobucket.com/albums/f176/Astra131/DSC00891.jpg

I've decided to only keep the black dash as the interior will be stripped out at some point when I put the cage and bucket seats in.

I currently have a beige dash and prefer to have a black one.

Somebody is interested in the rest of the black interior. If for any reason they don't buy it, I'll put the parts up for sale on here.
http://i47.photobucket.com/albums/f176/Astra131/DSC00893.jpg

[Danny]

Thanks Richie.

Yes, lovely to have her back. Be even better to drive it again. Haven't driven it for nearly a year and won't get to have any fun until next year.

Be worth the wait though. :thumbsup:

[mick g]

Hi Danny, you must be well pleased with that mate.. Top job:thumbsup:

[Danny]

Yes I am, Mick.

Very, very pleased.

It's taken a lot of work (mostly thanks to Tony) but deffo worth it.

Really pleased it was seam welded as well. Shame most of it won't ever be seen, but you can't beat it for peace of mind.

BTW. The guy who has moved my Astra about while all this has been going on is a guy called Roger who has a recovery truck.

If you need a car moved in the South East give him a call on 077401 23495

[Danny]

While the Astra was being sorted I had to give the Mighty Metro (my daily driver) a bit of TLC.

I could hear the alternator bushes start to whine plus the car was starting to struggle when starting.

I bought another alternator which stopped working after a few days so I changed it for another one and it's been fine since.
Also stuck a new battery on for good measure.

While I was doing the alternator I fitted a new manifold gasket as well because after doing the tissue test I realised it was leaking.

The tissue test is where you hold a tissue near the manifold and if it flaps about at any point, the chances are the gasket is leaking from this area.

Although the Metro is pretty basic it is also compact and means you usually have to remove several components before you can get to the part you want to work on.

Righty ho. Here's the fun and games.
When I was doing the alternator I realised one of the two bolts holding it on had sheared off. After trying a few scrappies I couldn't get another bracket as they are usually scrapped with the engines.

Here's the blocked hole.
http://i47.photobucket.com/albums/f176/Astra131/DSC00901.jpg

So I bought a new drill which also handily came in a pack with an impact drill as well.
Cost £95 for the pair from B and Q which I thought was pretty good.

http://i47.photobucket.com/albums/f176/Astra131/DSC00903.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC00904.jpg

I drilled a pilot hole through the old bolt then used a bigger bit to drill the rest of it out.
Bolt in place.
http://i47.photobucket.com/albums/f176/Astra131/DSC00916.jpg

Here's the old manifold gasket.
http://i47.photobucket.com/albums/f176/Astra131/DSC00697.jpg

Old and new gasket.
http://i47.photobucket.com/albums/f176/Astra131/DSC00696.jpg

Due to space restrictions I had to remove the manifold anyway to get the alternator out.
http://i47.photobucket.com/albums/f176/Astra131/DSC00914.jpg

Here's the old and new alternator.
iirc the new alternator was about £60 exchange.
http://i47.photobucket.com/albums/f176/Astra131/DSC00706.jpg

I had to swap over the pulley from the old alternator to the new.
At the time I didn't have a vice in the garage so had to improvise by using my neighbour's pallets, some bungee ropes and a a peice of hoover tubing to get some good leverage.
http://i47.photobucket.com/albums/f176/Astra131/DSC00707.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC00708.jpg

The brakes were also squealing a little. This was a schoolboy error on my part because when I fitted new pads last year I forgot to run some emery paper over them to take the glaze off.
Anyway I've done that now and it appears to have stopped the squealing.

So, after having the manifold and alternator off three times it's now all back together and running fine.
http://i47.photobucket.com/albums/f176/Astra131/DSC00917.jpg

My only concern was a small amount of coolant had gathered at the base of the radiator.
It may have been where I had knocked a hose, but I'll keep an eye on it anyway.
http://i47.photobucket.com/albums/f176/Astra131/DSC00908.jpg

Only other thing to report is for the first time ever I had a puncture in my own car at the weekend.
It must have happened while I was driving along and put a fair size rip in the tyre.
http://i47.photobucket.com/albums/f176/Astra131/DSC00918.jpg

And finally I treated little noddy car to a wash.
http://i47.photobucket.com/albums/f176/Astra131/DSC00712.jpg

As an aside my girlfriend has told me to hurry up and put the Astra back on the road as she would rather be seen in the Vauxhall than the Metro lol

[Danny]

Must say a big thank you to Screamer69 as well who kindly gave me a bolt for the alternator at short notice.

Unfortunately it was too big but was very nice of him anyway. Jay, you're a top bloke. :thumbsup:

[James C]

Things are looking up Danny

Restored GTE - check
Own home - check
Lady friend - check

:grinning-smiley-043

It can only get worse from now I'm afraid - gardening, DIY, new carpets, decorating..........= no time

[Danny]

Lol, thank you, James.

It's taken a lot of work to get here, but yes, finally things are coming together. :thumbsup:

[Danny]

About time for an update on possibly the slowest project on here lol, but I'm getting there.

Righty ho, to recap I want my Astra to be a track/road car.

Not done a massive amount but at least it's a step closer.

The car's still on my dad's drive as I've been sorting out my garage in preparation for the Astra's arrival. (I'll do a quick thread on the garage in a mo)

I visited Kent the other week and stripped the Astra out.
Some of the interior will be up for sale soon, but I'm currently helping another member out with bits, so bear with me.

The front of the car is now solid it just has a few issues here and there which I'm aiming to get sorted in time for Billing next year when I want the car to be predominately finished by.

Here's how it's looked for ages. And yes that is a wheel clamp. My parents' house also has CCTV. Can't be too careful.
http://i47.photobucket.com/albums/f176/Astra131/DSC01507.jpg

http://i47.photobucket.com/albums/f176/Astra131/DSC01508.jpg

BEFORE
http://i47.photobucket.com/albums/f176/Astra131/DSC01510.jpg
AFTER
http://i47.photobucket.com/albums/f176/Astra131/DSC01568.jpg

Rusty bits. You can see where the lower arch panel was welded on a couple of years ago.
http://i47.photobucket.com/albums/f176/Astra131/DSC01564.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC01543.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC01539.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC01525.jpg

I also treated the old girl to a new cover once I'd finished.
http://i47.photobucket.com/albums/f176/Astra131/DSC01571.jpg

A while ago my dad and I tidied the garage whereby I put my 20XE engine on a pallet with wheels attached to make moving it around easier.
Here's a pic of me wondering how the hell I'm gonna put this car back on the road.
Astrayorkie has promised to help me if I make him lots of tea and by him some biscuits, so I should be alright.

I'm also babysitting Astrayorkie's Tigra at the mo (explained in another build thread I'm gonna post in a mo) so it's all good.

To help me strip the Astra put it back together I treated myself to this Halford's professional socket set. Read loads about socket sets when deciding which one to buy and this one looked good for the money as it cost £99, reduced from £199.

If any of the sockets break Halford's replace them for free no matter how many times they break.

http://i47.photobucket.com/albums/f176/Astra131/DSC01518.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC01524.jpg

Very handy star bits and others.
http://i47.photobucket.com/albums/f176/Astra131/DSC01523.jpg

Star bits helped take off the seat belt bracket
http://i47.photobucket.com/albums/f176/Astra131/DSC01533.jpg

Next job is to get it back to mine, take off the sound deadening and generally clean up the interior and take out the dash before taking it back to Kent so my mate Tony can sort the rest of the bodywork.

This will involve plating over the sunroof or getting a second hand skin and spraying the inside of the car.

And fitting the roll cage and bucket seats, which I need to get retrimmed first.

Not much then lol, but hopefully done for Billing.

[Danny]

FFS

Trying to post pic of me in garage which didn't come up but photobucket not playing ball.

I'll do it tomorrow.

[DarrenH]

hello stranger !! good to see the astra is still in your thoughts and not abandoned !

but if you are starting an astra project "slow off", my silver astra has sat in a garage for a year, all i've done is start it up to drive to the MOT!

[Danny]

Lol, yeah slow off sounds good to me, Darren.

I hope you and your lady are well.

The project's slow for all sorts of reasons but things should speed up next year.

[Danny]

Here I am looking at my engine wondering how I'm gonna put my car back together lol

Sorry it's slightly out of focus. I'd been messing with my camera's settings.

http://i47.photobucket.com/albums/f176/Astra131/DSC01341.jpg

[Danny]

Yes it really has been more than a year since I posted in this section of the site.

However, a house purchase, work and the fact the car was 130 miles away meant progress was non existent.

This all changed last weekend when a cunning plan was hatched to bring my Astra home.
Due to the house taking priority (Nothing major is required, just tidying the garden, buying bits and peices etc) progress on the Astra will still be slow, but
at least some things will be done.

Astra's engine bay has already been welded and sprayed after the bulkhead split and my intention is to use the car as a road/track day toy.
Generally speaking next jobs will be:
Remove floor sound deadening
Replacr beige dash with a black one I have
Sort various rust spots inside the car and around inner arches
Fit roll cage and bucket seats
Freshen up engine (nothing major, not sure what spec yet)
Put car back together and enjoy.

Due to not posting for ages, I hope to have made up for it by including lots of piccies.

The car has stood undercover on my Dad's drive for about three years.
http://i47.photobucket.com/albums/f176/Astra131/DSC02245.jpg

It lives! Yes there really is a MK2 Astra GTE under there. The Flora tubs at the front of the bay were to level a board I put over the empty engine bay to prevent the rain from puddling in this area.
http://i47.photobucket.com/albums/f176/Astra131/DSC02249.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC02256.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC02255.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC02251.jpg

The last time it was at a show.
http://i47.photobucket.com/albums/f176/Astra131/DSC02250.jpg

After moving the Astra on my own while suffering from a Mancold (only the lads on here will understand what a Herculean feat that was) I swept the drive as thank you to my Dad for putting up with it.
http://i47.photobucket.com/albums/f176/Astra131/DSC02254.jpg

Somewhere down the side of the garage are the wings, bumper and bonnet. (Bonnet just visible)
http://i47.photobucket.com/albums/f176/Astra131/DSC02246.jpg

After retrieving the panels and putting them in the garden, I borrowed my mate's van and got the trailer we hired.
http://i47.photobucket.com/albums/f176/Astra131/DSC02247.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC02263.jpg

I say we, because my Astra wasn't the only Mk2 being moved that day, but more of that in a mo.....

After pushing my Astra into the garden we winched it onto the trailer.
http://i47.photobucket.com/albums/f176/Astra131/DSC02266.jpg

The engine, panels and a few tools (including my mate and me! lol) were then put in the Transit.
http://i47.photobucket.com/albums/f176/Astra131/DSC02264.jpg

Here's my berk of a mate Dale with the Astra and his van.
http://i47.photobucket.com/albums/f176/Astra131/DSC02267.jpg

And here's me with the Astra
http://i47.photobucket.com/albums/f176/Astra131/DSC02269.jpg

After safely tucking the Astra up on my drive, we then loaded another Mk2 onto the trailer.
Yeeesss, it's at this point I can reveal Astrayorkie's track day project has been languishing at my house, but has now been moved to a secret location
where it is due to be finished.
I think you should leave it like this Liam!
http://i47.photobucket.com/albums/f176/Astra131/DSC02271.jpg

On the trailer.
http://i47.photobucket.com/albums/f176/Astra131/DSC02275.jpg

As an added bonus I managed to nab my Dad's hardly used and antique grinder for my garage.
I love the bit where it says for service see Yellow Pages!
http://i47.photobucket.com/albums/f176/Astra131/DSC02257.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC02261.jpg
http://i47.photobucket.com/albums/f176/Astra131/DSC02260.jpg

Hopefully now the car's home some progress will be made rather than none at all.........

[BenH]

After pushing my Astra into the garden we winched it onto the trailer

Lol sounds all too familiar, looking forward to seeing this come together.

Top secret location... Is that Area 51?

[1800turbogte]

Cool thats a common site for me a MK2 on a trailer. Great to see some progress, your car looks well Danny concidering three years on a driveway.:)
What are the plans?
Keep the pics coming.:)

Chris

[Harvey]

Nice one Danny, it'll be back on the road in no time. Looks like you had fun collecting it.

[dancedj]

Great Danny Progress :) Good luck

[beegee]

Should be a good'un with the amount of work you have already put in to this car!

[Danny]

Thank you for all the kind comments.

BenH, it's not Area 51, it's somewhere even harder to find than that!

The car has already had loads of welding but unfortunately has a ripple down the nearside which can be seen in the sunlight.
A friend of mine has his own bodyshop so if I help and feed him with tea and biscuits he should do me a decent price to sort the rest of the bodywork issues.

I'm still learning when it comes to mechanics and quite daunted by the whole project TBH, but nothing ignorance, lots of posts on here and a big hammer won't overcome.

Sorting the bodywork is the priority, then swapping the dash, refurbishing the rear axle, sorting brakes, undersealing, fitting cage and buckets, rebuilding engine and putting it back together.

Not much really!

[BenH]

BenH, it's not Area 51, it's somewhere even harder to find than that!

Pmsl, yes it is!

Be good to get them all on the track together, Bedford next year or the year after lol ?