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Author Mates "Weekend fun / Track Car"
Ste L
Member

Registered: 3rd Jul 06
Location: Manchester Drives: 106 16v Rallye
User status: Offline
29th Aug 07 at 12:52   View User's Profile U2U Member Reply With Quote

From the beginning, I have got a cav SRi sat on my drive with lots of goodies on the engine but the body is shot and finally decided I wanted to do something with it.

Monday 6/8/07. So whilst driving to Aberyswyth I asked Namkeaps to have a look for a decent looking corsa shell 10 minutes late I had won one on ebay:







Went to pick it up and was pleasantly surprised at just how good a condition it was in for 170! Also decided to go half's with Namkeaps on the whole project.

The bad bits:
Both doors have been bent back and started to rust on the bends.
Two small (less than 5p) spots of rust on the boot.
A couple of very minor dints.

The good bits:
The 1.2 engine runs well.
The shell its self has no rust what so ever.
The sills look like they have never seen a jack!

A couple more shots:






Tuesday 7/8/07:

Made the first purchase, one of many more to come:


Started stripping the interior out:


Namkeaps managed to smash the windscreen. Bit of a pint in the arse - but not the end of the world lol:








Wednesday 8/8/07:

Ok so we hit our first set back today! On the way home from the unit last night I got a phone call from Namkeaps asking if I could tow his astra off the motorway. Get there and have a quick look, you could roll the car backwards, but wouldn't move forwards and if you tried to drive forwards it would hop and skip and bang alot. So rang the AA who said they would have a flat bed with us after 1.5 hours. So sod that, flew up to work, picked up the trailer and within the hour the astra was back outside Namkeaps house.
Went up after work today to have a look, fearing it was going to be the 4th gearbox in 3 months. Turned out to be the drivers side calliper, the top securing bolt had come out and the bottom one was loose so was sitting against the wheel. Few bolts later and all is right again.

So to days purchases are:
CV's

Strengthening plates

Engine mount kit

And a 2 1/4" Bore Twin Box Ashley Exhaust System .
All courtesy of Chris Astley Motorsport.

Friday 10/8/07:

Out with the old, ready for a good cleaning ready for the welding, underseal and maybe a spot of paint.





New remote control engine crane comes in very hand:






The donor:




Sunday 13/08/07:

Didn't manage to get too much done over the weekend, works van popped its clogs on Friday and also had a few problems with the roll cage, any how picked it up and gave it a trial fit. Finished cleaning out the parts I wanted from the cav, and stuck all the rubbish from the corsa in it.

Only a couple of pictures:





The super hi-off road corsa


Poor old girl, still sits nice and low:



Monday 14/08/07:

Time to give the interior, bay and underside a clean to see what kind of condition the shell really is in. Amazing what a bit of cleaning can do:









Picked up some bucket seats, corsa subframes and also dug out my old harnesses:





Tuesday 15/08/07:

Today was just the start of the prep work for some welding, painting and fitting of the roll cage:





I now officially hate spot welds the damn things just seem to hold on and on
:confused:


Friday 17/08/07:

Finished removing rear seats brackets to help with mounting the cage, also removed the heater matrix and its controls ready for a switch panel, also stripped the loom of the non essentials like the radios wiring, all the heater controls wiring, boot wiring and finally for today preped it for some of the welding that needs doing.

Looked at a quick rack from Deamon Tweaks thought they would be a bit more exspensive so think I will be ordering one whilst there is plenty of access in the engine bay.

Pics:






Saturday 18/08/07:

Today was mainly aimed at getting the welding done on the interior ready for painting inside and the underside. Got 95% of it done, just got 6 small bits left to weld but ran out of wire just as it was time for the shops to shut :cry:




Incase your wondering why all the sparks, we were using a gas less welder as the big mofo's voltage regulator has packed in so was just blowing holes in the thin steel


Had one small set back forgot to remove the plastic connecting pipe that sits between the filler cap and the tank, wondered where the 'extra' smoke was appearing from msl:





Wednesday 22/08/07:

Got all the interior welds cleaned up where needed and gave the floor area a coat of primer ready for a bit of paint.





A few more parts arrived today:










Friday 24/08/07:

Well didn't get what I wanted to do tonight, but on the other hand got alot more done instead was going to concentrate on painting this weekend.
Finished stripping the parts of the cav, suspension, full custom built stainless exhaust system, engine, gearbox, ecu, loom and accelerator cable. Didn't get too many pictures as I was working alone apart from a mate who popped in just in time to finish dropping the engine, not too bad though only too 3 hours 15 minutes:


Stubborn H frame bolt soon changed its mind when the oxyacetylene came out




One of a few reasons why the cav shell has past it, suppose its one of the problems of towing way too much weight and carrying tools and 3ton jacks round in the boot:




Sunday 26/08/07:

First coat of paint on the interior.





Monday 27/08/07:

Finished off painting the interior today. Also Waxoiled/undersealed the underside too. Got the rear suspension sorted too.











Ludacris Turbo
Member

Registered: 28th May 04
Location: High Green, Sheffield
User status: Offline
29th Aug 07 at 13:04   View User's Profile U2U Member Reply With Quote

Cool thread! can't wait to see it finished!
WMCMoo
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Registered: 22nd Sep 06
Location: Rushall, West Midlands
User status: Offline
29th Aug 07 at 13:19   View User's Profile U2U Member Reply With Quote

wicked thread mate, wish i had the time and money to do summat like this ohh and the knowledge lol
namkeaps
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Registered: 25th Jan 06
Location: manchester
User status: Offline
29th Aug 07 at 14:58   View User's Profile U2U Member Reply With Quote

it aint cost us as much as you think. woody@dc had the idea and we discussed it and we are now going halfs on it .... so far i dont think its gone over 1500. mainly due to already having the engine and a couple of other bits which yet we do not want to say what they are
-wylo-
Member

Registered: 4th Oct 04
Location: Dunfermline
User status: Offline
29th Aug 07 at 17:29   View User's Profile U2U Member Reply With Quote

Love threads like this. Great progress so far, wish i had enough space and skillz to do this!
Nath
Member

Registered: 3rd Apr 02
Location: MK
User status: Offline
29th Aug 07 at 17:55   View User's Profile U2U Member Reply With Quote

Ace thread!!

Also:



Love it!
dan_c4rsa
Member

Registered: 12th Dec 06
Location: North Yorks Drives: MK3 Seat Cupra
User status: Offline
29th Aug 07 at 18:06   View User's Profile U2U Member Reply With Quote

i want that crane too
P1CK4D
Member

Registered: 19th Jun 06
Location: Around Essex Somewhere
User status: Offline
29th Aug 07 at 18:11   View User's Profile U2U Member Reply With Quote

Looks brilliant! So jealous tho. Would love to have the space and knowledge to do something like this myself!
Whittie
Member

Registered: 11th Aug 06
Location: North Wales Drives: BMW, Corsa & Fiat
User status: Offline
29th Aug 07 at 18:14   View User's Profile U2U Member Reply With Quote

Good thread, will be following this one!
dan_c4rsa
Member

Registered: 12th Dec 06
Location: North Yorks Drives: MK3 Seat Cupra
User status: Offline
29th Aug 07 at 18:15   View User's Profile U2U Member Reply With Quote

give it a crack

i did my mk1's nova conversion in like a 5 x 7 metre garage. is so much fun learn as you go!

and as for that warehouse bloody hell i'd be in heaven. good project. take it offroading on those stilts! before you do anything to it!

[Edited on 29-08-2007 by dan_c4rsa]
Ben ev
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Registered: 23rd Oct 05
Location: kingslynn / torquay
User status: Offline
29th Aug 07 at 21:48   View User's Profile U2U Member Reply With Quote

the universal lambda's are wank. better off pulling a genuine one off something else
Ste L
Member

Registered: 3rd Jul 06
Location: Manchester Drives: 106 16v Rallye
User status: Offline
29th Aug 07 at 22:11   View User's Profile U2U Member Reply With Quote

bit of an update..

i bob down tonight to have a nosey and help out..

fitted valver brakes, some wheels, and sanded cage down and primed it..

will post pic's up when woody upload's them
ChrisBoom
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Registered: 6th Dec 06
Location: Highland
User status: Offline
29th Aug 07 at 22:24   View User's Profile U2U Member Reply With Quote

How much underseal did it take to do that? Need to underseal mine soon, bought 5 litres, think that might be enough
Ste L
Member

Registered: 3rd Jul 06
Location: Manchester Drives: 106 16v Rallye
User status: Offline
29th Aug 07 at 22:26   View User's Profile U2U Member Reply With Quote

5 litre's should cover it i guess lol..

could do with getting around to doing my own corsa
ChrisBoom
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Registered: 6th Dec 06
Location: Highland
User status: Offline
29th Aug 07 at 22:46   View User's Profile U2U Member Reply With Quote

quote:
Originally posted by Ste L
5 litre's should cover it i guess lol..

could do with getting around to doing my own corsa


Haha, thats good then.

Take it you had it up on the ramp for the underside? Need to wait till my crossmember is welded before I shift the car, then I can get it on a ramp.
Ste L
Member

Registered: 3rd Jul 06
Location: Manchester Drives: 106 16v Rallye
User status: Offline
29th Aug 07 at 22:53   View User's Profile U2U Member Reply With Quote

i dont think they did, they haven't got a ramp...

would of just jacked the front of the car with the engine hoist, i would of though
willay
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Organiser: South East, National Events
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Registered: 10th Nov 02
Location: Roydon, Essex
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30th Aug 07 at 07:03   View Garage View User's Profile U2U Member Reply With Quote

that is interesting
namkeaps
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Registered: 25th Jan 06
Location: manchester
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30th Aug 07 at 07:13   View User's Profile U2U Member Reply With Quote

underseal was put on while on axel stands afaik (i wasnt there at the time to help out) but it was put on as the pics show am sure of it
Corsa_Carl
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Registered: 8th Oct 04
Location: Darlington
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30th Aug 07 at 09:47   View User's Profile U2U Member Reply With Quote

wot a thread !!! cant wait till its finished

your car looks amazing to ! would luv it
namkeaps
Member

Registered: 25th Jan 06
Location: manchester
User status: Offline
30th Aug 07 at 13:02   View User's Profile U2U Member Reply With Quote

cage was in a pretty sorry state. bashed about so gave it a quick rub down with the help of ste and primered it up ready for a lick of paint. possibly tonight or tomorrow that will be done

its going to be black as to continute the black/white theme of the car
richard_cooper
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Registered: 31st Jan 07
Location: Mansfield, Nottingamshire
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30th Aug 07 at 15:13   View User's Profile U2U Member Reply With Quote

Good project
John G
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Registered: 18th Jul 05
Location: Wirral, Merseyside
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30th Aug 07 at 17:34   View User's Profile U2U Member Reply With Quote

is this the 4th corsa you were goin on about paul??

if so fuckin ace and best one youv had so far and uber fast progress,

how you gettin on after the women crashed into
bieransri
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Registered: 13th Apr 06
Location: Kidsgrove, Staffordshire
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30th Aug 07 at 17:41   View User's Profile U2U Member Reply With Quote

wish i knew how to get my seat brackets off, mine are being a pain.
Ste L
Member

Registered: 3rd Jul 06
Location: Manchester Drives: 106 16v Rallye
User status: Offline
30th Aug 07 at 17:44   View User's Profile U2U Member Reply With Quote

quote:
Originally posted by bieransri
wish i knew how to get my seat brackets off, mine are being a pain.


spot weld drill or grinder...
bieransri
Member

Registered: 13th Apr 06
Location: Kidsgrove, Staffordshire
User status: Offline
30th Aug 07 at 17:45   View User's Profile U2U Member Reply With Quote

spot weld drill i have no idea how to use. tried it on one n it went straight through, tried the grinder got just about all the way through and its not budgeing

anyway looks bit like the corsa version of mine inside

[Edited on 30-08-2007 by bieransri]

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