Announcement

Collapse
No announcement yet.

Pondering upon some modifications while restoring the bulkhead...

Collapse
X
 
  • Filter
  • Time
  • Show
Clear All
new posts

  • Pondering upon some modifications while restoring the bulkhead...

    I have ordered this:



    And will order a pair of these bottom mounts:



    To restore the front end because it has some rust and one of the bottom mounts has partially come loose....

    While replacing this I am taking the engine out and get the whole engine bay sorted and all rusty bits cleaned up.

    Over at where I work we have a hydrolic sheet folding bench and cutting machines, so I can make beams etc. I have already planned on making the GTE front crossmember myself (the one in front of the radiator) and was thinking of creating a subframe to get the front end stiff as concrete. Made a sketch and wondered what you guys think of it...

    This part I planned to weld in place as it will not be in the way:



    It'll brace the two bottom mounts together nicely and I already have a Vectra/MK3 rear gearbox mount with rubber, which has two threads downwards instead of two bolts upwards (which are a real pain to fit!!)

    And then I planned on connecting the front to the back side of the engine bay with two beams that can be removed, plan to weld in some welding nuts to bolt them on to. Off course these will be in the way if I plan to do serious engine or gearbox work...

    Here's the complete drawing then:



    The beams will be made of two layers, one folded as a beam, the other (bottom end) just flat and spotwelded together, just like the real thing... Thought of using some 3mm or 4mm material, or 4mm flat and 3mm folded....

    Here's a MK3 bottom pic as a reference of the idea:

    Last edited by Vinci; 06-06-2012, 12:28 AM.

  • #2
    Re: Pondering upon some modifications while restoring the bulkhead...

    in theory i think its a great idea aslong as you can get it to clear all the necessary items. the lower cross section (running from wishbone to wishbone) was something i was planning to do.

    the only negative i can think of is adding allot of weight to the front end of the vehicle, although it atleast it will be low down below the axle line

    i think the mk2 astra missed this rigidity badly, having owned a poweful mk3 astra it felt more sure footed at the front, and ditto for my mk2 cavalier which had a simialr setup to your drawings.
    Last edited by DarrenH; 04-06-2012, 11:24 PM.

    Comment


    • #3
      Re: Pondering upon some modifications while restoring the bulkhead...

      Cheers, will try to make it as light as possible, hence the folding 3/4mm thick sheet (maybe 2mm will already do?) Wonder how thick the material is of a MK3 subframe...?

      Shouldn't have to add more than 30-40 kilograms...

      I think I have planned it out well enough to clear all the parts.

      How about that engine mount at the timing belt side? Was also thinking about taking the little box section off the side and use a MK3 mount there as well... I do think it is better as well...

      Last edited by Vinci; 04-06-2012, 11:59 PM.

      Comment


      • #4
        Re: Pondering upon some modifications while restoring the bulkhead...

        would the mk3 mount not fit under the chassis and on the mk2 on the inside edge of the chassis. Both are at different heights are they not? you'll have a few problems sorting that mate.

        Comment


        • #5
          Re: Pondering upon some modifications while restoring the bulkhead...

          Originally posted by auldyin1998 View Post
          would the mk3 mount not fit under the chassis and on the mk2 on the inside edge of the chassis. Both are at different heights are they not? you'll have a few problems sorting that mate.
          You mean that engine mount mate? The MK3 mount is longer, the distance between the chassis and engine is the same or just about the same on the MK2 and MK3. So the MK3 mount will reach to under the chassis of the MK2, where it is simple enough to weld some threads in.... I will just drill large holes in the chassis, then weld a little plate in where the nuts are already welded on top nice and strong....

          Any of you worried? I'm not!

          Comment


          • #6
            Re: Pondering upon some modifications while restoring the bulkhead...

            I ordered most of the bits from the Opelclassicparts Ebay shop in Germany, nice place to get original material to make pro repairs!! And pretty cheap too!!

            Comment


            • #7
              Re: Pondering upon some modifications while restoring the bulkhead...

              Guy that sold me the engine two weeks ago has about 7 or 8 MK3 subframes and is willing to sell me a complete one for just €30!! I would be crazy not to hack a MK3 frame up to fit the MK2. Will keep all the MK2 stuff though, wishbones, wishbone mounts. Basically going to work out the same plan as above, but just by using bits from the MK3 frame and if necessary combine with home made stuff....

              Comment


              • #8
                Re: Pondering upon some modifications while restoring the bulkhead...

                Just wondered what the regular bolt sizes are for the MK3 subframe. And also the rear wishbone mount bolts on the MK2, and the engine mount holes.... Probably not a bad idea to keep them a Vauxhall standard size as much as possible and also not a bad idea to order enough new nuts and perhaps bolts as well (or collect them from a scrapper) before I start the project....

                Just back from a three week camping trip to France, for which I had to borrow my father in law's Fiat Stilo. We all thought it was a better idea since the engine in my MK2 was recently replaced and the rust damage was not bearing us all much trust. The Stilo left us alone the second week though, broken front spring. Happened when it was standing still! LOL We were just sitting besides the car and it was like a bullet was fired, so I ducked behind the chair afraid there was more to come... After a little ride I noticed there was definitelty something wrong as it had a little rattle, then opened the bonnet again for another inspection and saw the air filter box was open and broken here and there (still before I was certain about the spring) Had no means there so went to a Fiat dealer, put it on the lift and picked up the bottom winding from the spring... And the boot refused to open many times, the drivers seat refused front/back adjustment many times, the seats are hard and not shaped well, space is more limited everywhere than expected judging from the external size of the car.... Even though my MK2 isn't exactly shipshape at the moment it was an amazing sensation to be able to ride in it again today!! Don't want the embarrassment again next years holiday!!

                Comment


                • #9
                  Re: Pondering upon some modifications while restoring the bulkhead...

                  Ideas stilling shaping in my head, been pondering upon going for the whole MK3 subframe and just weld in some nuts to place it, only the tracking width is a few millimeters wider, which will increase negative camber a slight bit, plus I'll need to use the MK3 driveshafts as well. But maybe the little extra negative camber will only improve cornering?? It would perhaps simplify things to just use the whole MK3 frame...or maybe not...

                  Been looking for new wishbones as well, as posted in another thread I opened, but there seems to be a difference between the 16v GTE wishbones and all other models. Anyone know what this difference is??

                  Comment


                  • #10
                    Re: Pondering upon some modifications while restoring the bulkhead...

                    As far as I know mk2 and mk3 driveshafts are the same?

                    Comment


                    • #11
                      Re: Pondering upon some modifications while restoring the bulkhead...

                      No mate, I have a pair of MK2 shafts and a single (thought as spare) MK3 shaft and these are 8mm longer. For road use they can be used, but for racing or rallyeing it'll definitely give problems.... Some epxert users on the Dutch forum have proven this after many users wondered about the compatibility in a thread over here. No doubt they are different...

                      Comment


                      • #12
                        Re: Pondering upon some modifications while restoring the bulkhead...

                        yeah shafts the same.

                        i think what the mk2 really lacks is chassis (engine bay) rigidity and castor

                        Comment


                        • #13
                          Re: Pondering upon some modifications while restoring the bulkhead...

                          8mm is nothing, the CV's have bags of room to swallow that .... if you need to, just cut a new circlip groove further in like I did on the Corsa to reduce the spacing by 10mm.

                          Comment


                          • #14
                            Re: Pondering upon some modifications while restoring the bulkhead...

                            The 8mm is mainly a prob when using MK2 shafts in a MK3, then they lack this length and they break quicker. It's been proven here a few times. MK3 shafts in a MK2 can cause the differential bearings to prematurely die from the banging, especially on lowered cars that are used on the track. Mind that I just quote the info, only first hand information is that I have seen they are different in length by about 8mm, so I am certain of that. The CV's can swallow the length difference up to a certain point, sure. On road cars it won't be a problem, just under the heaviest of circumstances it is not advised...

                            Comment


                            • #15
                              Re: Pondering upon some modifications while restoring the bulkhead...

                              Originally posted by DarrenH View Post
                              yeah shafts the same.

                              i think what the mk2 really lacks is chassis (engine bay) rigidity and castor
                              You mean I could achieve something on my mod by altering the caster? So I suppose you mean it lacks positive caster?

                              Comment

                              Working...
                              X