92 Kadett 4Dr Expression

[clarkey]

Re: 92 Kadett 4Dr Expression

All connected and working. A bit of tiding up left to do but dash is in at last. Heater box not perfectly aligned behind dash for vents but close enough to be effective. Modified Kadett column covers fur use with Astra Dash. Some pics.

[clarkey]

Re: 92 Kadett 4Dr Expression

As said I need to relocate front speakers as Astra Dash has no location for speakers like kadett dash did. Going to put them into back corner of door pockets.



Kept front pockets from other kadett and did a trial install to see how they looked.



Very happy with result. Am going to fit these and keep originals.

[clarkey]

Re: 92 Kadett 4Dr Expression

Got roof antenna fitted. Went with an Astra G Coupe base with modified antenna from Vectra B. Looks ok and works well.





Also fitted stereo. Connected rear speakers temporarily and all checks out and works as it should.

[clarkey]

Re: 92 Kadett 4Dr Expression

Door speakers are in and driver door window reg fitted.



Also finished dash build up.



Need to find a way to secure dash below heater controls to tunnel and then it's on to making center console fit.

[clarkey]

Re: 92 Kadett 4Dr Expression

Had my Convertible out for NCT test this morning. One of testers did not make it in so have to rebook test. At least test will be free to compensate. It will be some time yet before loon is test worthy.

[clarkey]

Re: 92 Kadett 4Dr Expression

Lower dash secured to tunnel.



Center console sits in place very well. One issue that needed resolving was handbrake. Leaver would not go down fully as was hitting console when in place. got around it by moving handbrake leaver mount point. Tried point for rear bolt first but leaver would not push down enough. Moving front mounting point up did the trick.





Also got power steering pump assy. Thinking along the lines of hiding pump under lh front valance behind front bumper along the lines of early Vectra C.

[clarkey]

Re: 92 Kadett 4Dr Expression

Front carpets are in. Fitted inner sill covers and also used front inner covers from Astra.





On to seats. Driver seat was torn on bolster but a mate gave me a good passenger seat back. Had to strip cover off both seat backs & move good one across.





Interior is pretty much finished now.

[clarkey]

Re: 92 Kadett 4Dr Expression

Made fair progress with steering. Found a spot for pump just to right of radiator. Modified pump mount bracket slightly before putting into place and marked spots for mounting holes on front lower crossmember. Bolted bracket in first, then attached pump.









Next the hydraulic pipes needed to be modified to suit. I made a suitable return pipe using the end of the Astra G return pipe that attaches to pump and joined it to kadett return pipe. For feed I made up a template pipe by again using different ends of two pipes to make it into one. Trial fitted it and it is spot on. It looks like this.



The pump has 4 wires. A heavy red constant live, A heavy brown for earth, a light black wire for ignition live and a blue and white for battery warning light. Used some wire from a Vectra C power steering for constant feed. Also included 80a fuse.









Ran wire to alternator for blue and white and connected black wire to wire left from auto connection. Ignition feed and already fused.



Earth for steering attached to back of horn mount bracket. Just needed a longer bolt.



Couldn't resist starting it up to check all was working with temp pressure pipe so gave it ago. Pump kicked in perfectly and have power assistance. Knocked it off and removed pipe and sent out to have hydraulic hose made to fit.

[clarkey]

Re: 92 Kadett 4Dr Expression

New hose collected and fitted.







Topped up with oil and job done.

[clarkey]

Re: 92 Kadett 4Dr Expression

Noticed the wiper motor not working correctly. Checked the connection and found wired differently on Astra loom than kadett. Connection on left from Kadett. Connection on right from Astra loom now in car.



Wire colours are the same so I just put wire in same positions as Kadett loom and now working correctly.





Also changed repeater lights on wings. Went with Frontera B items.

[clarkey]

Re: 92 Kadett 4Dr Expression

Dug out a set of clear indicators from parts stash in loft in shed. Looks much improved.

[willie]

Re: 92 Kadett 4Dr Expression

Great work here James! The power steering looks a great job!

[clarkey]

It has been a while but I have gotten around to having rh sill replaced completely. Inner sill was very solid thankfully.









That is metal work completed. Now start saving for respray.