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Author Corsa Gsi From standard to XE
ryan_fowler1985
Member

Registered: 27th Jul 05
Location: Trevethin, Torfaen
User status: Offline
3rd Sep 08 at 03:34   View User's Profile U2U Member Reply With Quote

Been on here for a while now but havent put my project thread up as i spend most of my time over on mig but as this is a corsa site i thought id stick it up and see what your opions are.
Please bear in mind this is my everyday car and has been built on the road or in my 8ft wide garage I dont belive in taking it to a garage for anything except tyres test and tracking lol

I have copied most of this over from my other project thread on mig so some bits may not make much sense, i will be keeping it updated from now on tho on here

Thanks for looking
Comments welcome

Ryan










256mm cav sri calipers with grooved disks and black diamond pads.


before





after







Dbilas inlet manifold to fit to the 1600 before the xe was even thought about








Powerflow backbox


z16xe cover modified to fit






New wheels






And a bit of mud after the wales rally gb lol





[Edited on 03-09-2008 by ryan_fowler1985]
ryan_fowler1985
Member

Registered: 27th Jul 05
Location: Trevethin, Torfaen
User status: Offline
3rd Sep 08 at 03:45   View User's Profile U2U Member Reply With Quote

Dial rings fitted







New wheels again




a few with the astra rims



















And a few when clean.













A few before pics


front tyre in arch







My method of getting the trolley jack under a car lower 60mm lol



Like a 4x4






Damage to the inside of my front arches and arch liners



New springs and old



Camber bolts fitted


Is my tracking out? Both wheels looked like this



And how it is now job done, 40mm front 60mm rear





Randomly bought an xe off a mate






Don knew something was wrong here but he couldnt figure out what was missing


So we started on the box and clutch off you come and up on the stand




Jamie and don couldnt wait to get it apart and cost me money the buggers





Off with the head all looking good here








Jamie needed a rest now lol and the engine needed some sun



Off with the Crap sump gasket




Then ev turned up when the work was done in his crappy french car, and a very clean coat what a w*nker



Time to admire the beautiful scenery and weather, lol


Car and lazy people


Picked up some more bits looked at the mess then tidied up a bit.






The good thing about a corsa is it will still fit in the garage even tho its full of crap


To the workshop of Fowler Engineering Ltd complete with air holes:doh:






And some of the working conditions i have im sure they are better in the third world countries





Before painting with some of the old flaky paint removed


Decided to go for black this time as i wont show up the dirt as much and if it does flake it wont matter as much







Been trying some colours for the cover, not sure what to go for yet, i was thinking red plug cover with white lettering and a grey rocker but darker than the car colour more anthracite, what you think? excuse the crap paint job it will be rubbed back and done properly when i decide for definate






new valve springs


compressing the spring, out with the old








new and old no difference in height but the new ones are noticably more stiff


one done






































Filler primer to cover imperfections






First coat



Clear coat on




The belt cover im happy with but the rocker has some run marks

Plug cover


How it should look













And my dodgy light, simple yet effective



ryan_fowler1985
Member

Registered: 27th Jul 05
Location: Trevethin, Torfaen
User status: Offline
3rd Sep 08 at 03:56   View User's Profile U2U Member Reply With Quote

Type 2 mount kit and rubber mount, and i thought as im doing the engine id get some shiney bonnet lifters


Some progress of my night shift in work, being an electricain it was pretty obvious these were for home lol.
Measured and marked out the correct dimensions


Used the giant guilotene to cut up the plates, this comes in very handy at times




Out with the hand tools, and the noisey as hell air kit grinder set.


Bit of cutting and fileing later and i have these, the front one is a proper one i borrowed


Few more ready to be finished tonight.



Front bumper off to look for rust






Not that bad its pretty solid just surface rust which aint bad for a 12 year old car i was expeting a little bit at least.


Don decided to do some washing up under my bonnet with his lovely gloves



Bits removed lots more removed but was running out of tme too quick for photos


will it ever look the same again?






Loom and ecu removed ready, just need to get the immobiliser transponder thingy out at some point.




New engine ready for the in.


Then had a quick tidy up so all the tools are together






Not much left connected now



Out with the x16xe engine




empty bay cleaned up a bit




The 12 year old dirt was no match


Nice and clean






Found these plate already here for strength




Somewhere in all this crap is my tools


New engine bolted in






Plugs go in






Covers on quite happy with the outcome.




Random photo


More mess


Don used most of this can to clean things including the light bulbs for a smoke effect


Finding tools started to get a bit annoying


A factory fit finish








Who put the hammer in here?








AFter it was all running we came across a major leak from the oil pump gasket and had to strip it agin to change it
well some photos of my wiring, yesterdays and a few of progress from saturday taken by jamie as i forgot lol















up in the air to get the oil pump off






How i would like the rear end to look


Looking like a car again




And just for don some of my wiring, told you id solder them lol






The pas pipe then burst in tesco car park resulting in lots of smoke and oil lmao
the joint that has split on the pipe




where the pipe runs now




split on the joint


im thinking of running the new pipe between the manifold and the block and using 10mm hydraulic fittings to joint it to the 10mm pipe at the pump and at the point where it has broken.





ryan_fowler1985
Member

Registered: 27th Jul 05
Location: Trevethin, Torfaen
User status: Offline
3rd Sep 08 at 04:09   View User's Profile U2U Member Reply With Quote

Got it on the rollers and it was a bit down on power due to running a 1600 exhaust and eml light on














A few photos of interior work, more to follow

How the seats look after a clean








Seats out and carpet cleaned






Frames swap from old to new






Rounded this bolt off :doh: so had to get a new one


Heatedness


How it looks at the moment






As some of you may no, i got the car tidied up a bit and fitted the rest of the leather and set off on saturday morning on route to castle combe circuit.

Had a good day despite the rain and took the car out on the track for the first time and had great fun even with no grip


The car survived the track and made it home with no problems which i was more than happy with, but then on sunday on my way shopping locally the bottom end gave up on me and left me stuck with a big puddle of oil and some bits i collected off the road.




I havent had chance to strip it completely yet and find out exact damage but i will get photos hopefully tommorrow all i know is cylinder 1 is 3/4 up the bore and 2 3 and 4 are all around center

The engine as it stands at the moment looks like this




In need of a car for work i went out and bought this off a mate for a runaround,


The cav lasted one day then got swapped for this beast which will be my donor for its engine hopefully next week sometime, 82k miles dispac xe with no taps smoke or knocks at all even from cold.






So here we go again, progress will follow:doh:

the engine is out now ready for the new one begining of next week when i have alternative transport to drive.

The head is slightly damaged with 4 valve bent, also looks like something has entered chambers 2 and 3 somehow and marked the head. The piston is cracked twisted and in bits, the rod has blown to pieces and gone throught the baffle plate, sump and block in 2 places, also broke through my pas bracket

a few photos
Enjoy









Bent valves
















Crank scored




Got the engine out of the van and into the car but when it came to start it wouldnt go past tdc, found that somehow a nut had got in there

Old engine stripped of its useful bits and thrown in the back of the van


The engine bay of the corsa box left in






Engine in van being stripped ready for the removal






And in the car, red plug cover looks better than the yellow imo




Forgot the bloody rad


Saturdays work strip it back down after it was so close to driving


Reverse head xe anyone?




And the damage that is caused when a nut goes in the cylinder i was lucky it didnt do more damage by landing on the valve seat






Some of the mess we made, some how we managed to take up 6 gargaes with bits and cars lol


Head cleaned up ready for refit


Just over 70000 on an n plate


First trip after the rebuild i found this monaro i think my corsa will win


and a few photos i just came accros that i forgot about

Mite fit this one day


Ready for a good cleaning session




Leather all fitted




Decat pipe


Some spacers i knocked up













ryan_fowler1985
Member

Registered: 27th Jul 05
Location: Trevethin, Torfaen
User status: Offline
3rd Sep 08 at 04:14   View User's Profile U2U Member Reply With Quote

Brand new piper cams

New cams still with the phosphate coating on.






Old cams and lifters out with assembly paste on.




My other lifters ready to fit


Old bits


Bit more limited to space today than usually due to the local carnival, unfortunatly i have no photos of this as it went to quick lmao


More Lube


The engine was then timed back up and ran for 20mins at 2500rpm as instructed.

We then moved onto the new fan
Old one out for more space




New one on although the final position was the right of the rad due to bonnet shut.




At billing i managed to pick up a set of caps for 8 for my wheels, think they look alot better than the original ones


I have also looked into a chip to go in my spare ecu, ive ordered one that can be programed so the limiter will be moved to 8k
old ecu and the chip to be replaced




Rubbed back




Masked up ready for primer


The worst of the wheels as you can see its pretty bad


Halfrauds filler primered




Paint of choice for today, always found ive got a tidy finish from the can when using simoniz products to paint wheels


The back of the dodgy wheel sprayed, still rubbish but its all one colour and i aint worried as its the back







This was the bad wheel when i started now all done




The finish on one of the spokes




Back of the wheel




The other one all done






The run mark that annoyed me


enjoy, will get some tidy pics when they are back on the car.

not sure if i need to do anything with them now like g3 or just leave them and give them a damn good polish and wax?





















Hids fitted




As you can see my drivers side light is ever so slightly high lmao





ryan_fowler1985
Member

Registered: 27th Jul 05
Location: Trevethin, Torfaen
User status: Offline
3rd Sep 08 at 04:14   View User's Profile U2U Member Reply With Quote

At last this weekend i got around to a few of them jobs ive been wanting to do for a few weeks or even months lmao

my new crank sensor arrived in the post friday a nice metal one rather than the plastic one so i decided i was going to fit that along with my frot alloys now they are black , also i decided it was about time that i got my arse in gear and changed the sump gasket and rod bolts so i could treat the engine to some decent oil and a new filter as it was running on 15w 40 cheapo nasty oil which was making my lifters a bit noisy.

First of all my front wheels were kerbed and needed refurbing so after a rub back they looked like this





a bit of filler and some black spray paint they were almost like new


A few of the bits i needed to fit:
Stainless manifold shield i made on nights lmao lmao






Arp rod bolts and 8v bonded gasket, f20 gasket set to fit when i get a new box




Set about stripping the car down
Manifold off which was a pain in the arse with the pas still on, afterwards i realised it needed to come off anyway to get access to the crank sensor



Anti roll bar off seems to have taken a bit of a beating and gone flat lmao


Minging sump covered in oil and ****e, cleaned up real well but no photos :doh:





Car up on the ramps needed to remove the bumper to get near the ramps


made a bit of an oily mess that annoyed me as i got covered in it



And a few of the underside of the engine with the new bolts fitted










Ive got a few more little bits to finish off which i was gonna do today but its raining and the garage is a mess, gotta refit pas pump, fit arb with new polybushes, sort my exhaust blow and back box positioning, all will be finished this week ready for castle combe on saturday where i have 2 track sessions to abuse it.

ill get more photos as i go

cheers for looking, comments please
richard_cooper
Member

Registered: 31st Jan 07
Location: Mansfield, Nottingamshire
User status: Offline
3rd Sep 08 at 10:44   View User's Profile U2U Member Reply With Quote

Did you do this with standard lights ?


flybikeslee
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Registered: 2nd Jan 07
Location: Liverpool
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3rd Sep 08 at 10:58   View User's Profile U2U Member Reply With Quote

awesome build up mate, although i did prefer the old astra 6 spokes
Mark Prydderch
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Registered: 7th Mar 07
Location: Chester
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3rd Sep 08 at 11:01   View User's Profile U2U Member Reply With Quote

Remember seeing this at PVS, good work mate.
DannyB
Premium Member

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Registered: 6th Feb 08
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3rd Sep 08 at 15:21   View Garage View User's Profile U2U Member Reply With Quote

Nice, the astra wheels suited it so much better.
Ste L
Member

Registered: 3rd Jul 06
Location: Manchester Drives: 106 16v Rallye
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3rd Sep 08 at 15:53   View User's Profile U2U Member Reply With Quote

seen this on Mig - great project
Neo
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Registered: 20th Feb 07
Location: Essex
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3rd Sep 08 at 16:18   View User's Profile U2U Member Reply With Quote

Fantastic
ryan_fowler1985
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Registered: 27th Jul 05
Location: Trevethin, Torfaen
User status: Offline
3rd Sep 08 at 17:36   View User's Profile U2U Member Reply With Quote

cheers for the comment guys, i liked the astra wheels but i think the shape of them was too soft, would of had cesaros if i could find any bt the others came up first which i think looked good. The astra wheels are now on my girlfreinds black sport and will soon be done white so not gonna be getting them back lol

the headlights where done using depo replacement headlamps, it is also posible to do it with the valeo ones but they are harder to split apart
sand-eel
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Registered: 15th Mar 07
Location: carluke/braidwood--IRNBRULAND
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3rd Sep 08 at 18:37   View User's Profile U2U Member Reply With Quote

l15ter
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Registered: 1st Feb 08
Location: Berkshire
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3rd Sep 08 at 22:38   View User's Profile U2U Member Reply With Quote

quote:
Originally posted by flybikeslee
awesome build up mate, although i did prefer the old astra 6 spokes


yea x2 on that, when i was down 60mm i really like this car, didnt think the seats would look good being in a gray car, but they look fucking great, get the door cards done and keep up the good work
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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3rd Sep 08 at 23:00   View Garage View User's Profile U2U Member Reply With Quote

epic thread
ryan_fowler1985
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Registered: 27th Jul 05
Location: Trevethin, Torfaen
User status: Offline
3rd Sep 08 at 23:53   View User's Profile U2U Member Reply With Quote

ive got a few things flying round my head about what to do with the interior,posibly refit the gsi interior or get a half cage with 2 buckets. bit fed up of the cream getting dirty
ryan_fowler1985
Member

Registered: 27th Jul 05
Location: Trevethin, Torfaen
User status: Offline
10th Sep 08 at 20:09   View User's Profile U2U Member Reply With Quote

took the car to castle combe on saturday and got out on the track, first session was very wet and spun coming out of the first chicane , then had great fun in the dry.
Ive now got the car up for sale and im looking for around 1700 if it doesnt sell im gonna be putting some money into it and will be buying a cage, coilovers and a few other goodies

A few photos i took when i got back from combe






















For sale ad
http://www.migweb.co.uk/forums/cars-sale/371774-1995-corsa-gsi-c20xe.html

 
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