vauxhead
Member
Registered: 9th Oct 10
Location: Liverpool
User status: Offline
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Welcome to my track car project, the car is all fully built now and a build thread is on another forum but I thought Id do a thread on here to
19/9/10
Started life as poverty spec 1.0ltr with no power steering, ABS, sunroof or any electric toys, so it was an ideal starting point.
Was soon into the unit and stripped :
25/9/10
Engine/gearbox out and sold:
2/10/10
Then it was pushed outside to give the insides a good wash and clean out:
10/10/10
Up on stands ready for the suspension to be removed
15/10/10
working on getting rid of all the sound deadening, nasty job that took ages but got there in the end with a heat gun and thinners.
25/10/10
Won an OMP rollcage on ebay so when that arrived, set about getting it fitted:
And all the sound deadening is now gone too, debating on what colour to paint the insides tho...
Also I went on scrap yard mission and came back with the full EPAS setup, a set of rev counter clocks, a genuine gsi rear spoiler and some other bits and bobs all for a very reasonable price 
7/11/10
Picked up the exhaust system today, 3" bore stainless from the downpipe back, 
13/11/10
Been doing a bit more shopping :
Poly bushes:
Motorsport hubs:
High tensile wheel studs:
And have removed the wiring loom so it can be modified to run the LET:
16/11/10
Some more progress:
Rear beam off :
Front suspension off:
Fitting the rear spoiler:
Poly bushes fitted to lower arms:
And to rear beam:
BMW battery leads:
21/11/10
Engines mounts, tie bar spacers and cav rear anti roll bar
27/11/10
Not much of an update but picked up the chassis strenthening plates today and a set of tigra 5 spokes to use instead of the cesaros.
4/12/10
Been doing a bit of tidying up on the rear chassis rails as they where a bit grotty :
Buzzed all the rust off and then treated it all before etch primering and then stone chip coat
Before (both sides):
After:
Before:
After:
Before:
After:
And other side:
Also had the chassis plates welded in:
Tidying the odd bits of rust in the bay:
Engine mount on:
11/12/10
Drilled the front hubs and fitted the wheel studs today:
Need to do the rears next but going to upgrade to corsa C drums as they use a better bearing design.
22/12/10
Progress hasnt stopped on this, just slowed down due to access to the unit being a bit tricky:
But been getting on with fitting the cage:
And have a set of goodridge brake hose now
Once the cage mounts are all welded in, the inside can be painted.
Will post more bit later on
[Edited on 29-12-2011 by vauxhead]
[Edited on 29-12-2011 by vauxhead]
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Jon_C
Premium Member
Registered: 7th Dec 05
Location: Suffolk
User status: Offline
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Looks like a good project. Nice work so far
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Darryl H
Organiser: South Central
Premium Member
Registered: 19th Nov 09
Location: Camberley Drives: Porsche 944
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Looks good so far mate 
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belton
Member
Registered: 23rd Jul 09
Location: Kent
User status: Offline
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Looks really good so far mate!
The BMW battery leads is a good idea! Everyone usually just uses halfords wire. Can you use the BMW kit as a direct replacement? Making it mega OEM
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Col004
Member
Registered: 25th Jun 03
User status: Offline
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Looking good Tom. The car is finished and is a great job... Put together right!
Get the rest of the pics up matey
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DansCorsaSXi
Organiser: Yorkshire
Premium Member
Registered: 13th Jan 10
Location: Worksop
User status: Offline
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Good progress there mate.
Great work especially on the bay.
Star silver C20XE SXi Project thread
Smoke Grey Corsa GSi Project thread
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vauxhead
Member
Registered: 9th Oct 10
Location: Liverpool
User status: Offline
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Thanks lads !
Belton, I wanted to use the BMW distribution block in the bay but didnt bother in the end, the cable is overkill tbh, its proper thick lol.
Col, you should know me by now ha,
More progress:
31/12/10
Bit more progress on the cage feet :
Front ones shaped, cut and boxed to fit the floor nicely and will be using captive nuts for the bolts:
Will be boxing these ones in same as the front two and again two of the bolts will use captive nuts and the other two will go right through the floor:
Just need to sort the back stays out and the door bars, but cant do them until I`ve decided on the seats 
Corsa C rear brakes and stub axles fitted, no stupid split pin holding my wheels on thanks! :
And picked up these Spax RSX coilovers:
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Col004
Member
Registered: 25th Jun 03
User status: Offline
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Keep them coming... Did you get the mk4 
[Edited on 29-12-2011 by Col004]
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vauxhead
Member
Registered: 9th Oct 10
Location: Liverpool
User status: Offline
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Yeh mate I got the mk4 and love it !
9/1/11
Welders been out to play today so the cage feet are now part of the shell
The welds arent the prettiest as we only had C02 gas and not Argo shield, but they are now the strongest part of the shell 
Need to get them cleaned up and sealed, then can paint the inside.
Gauge pod for the dash too
13/1/11
Got the seats today
RMD Professional from www.rallydesign.co.uk
Full fibreglass shell, side mounted and very light!
24/1/11
Cage door bars now fitted:
Floor drain holes welded up:
Rusty patch cut out and new metal plate welded in:
Fitting the drivers seat runners:
Going to be redoing the seat mounts as not really happy with them and the passenger ones need moving back about 4 inches.
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bigron1988
Member
Registered: 29th Aug 09
Location: Southport, Merseyside
User status: Offline
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been waiting for a progress on this tom, keep the pics coming looking great so far
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3i_gaz
Member
Registered: 29th Nov 07
Location: Liverpool
User status: Offline
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Looks good this! looking forward to seeing it
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vauxhead
Member
Registered: 9th Oct 10
Location: Liverpool
User status: Offline
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10/2/11
welds sealed up and floor now painted in silver hammerite:
New fuel tank fitted with walbro 255 pump and new filter:
26/2/11
Flocked dash by Raj at Autoflock, ace job, really impressed with it
Also got the intercooler and rad to fit, not much room tbh and still need to find space for the oil cooler !
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Gary
Premium Member
Registered: 22nd Nov 06
Location: West Yorkshire
User status: Offline
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Looking good
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M Sutton
Member
Registered: 11th Jan 03
Location: Northamptonshire
User status: Offline
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Nice project!!
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Darryl H
Organiser: South Central
Premium Member
Registered: 19th Nov 09
Location: Camberley Drives: Porsche 944
User status: Offline
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This is starting to look awesome already!
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vauxhead
Member
Registered: 9th Oct 10
Location: Liverpool
User status: Offline
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Thanks lads, glad you like it
Sorry for the quality of the pics so far, they where taken on my phone, the pics from now on are off my cam.
5/3/11
Done a bit of painting today:
I used hammerite spray and it turned out alot better than I was expecting, the finish is on par with powder coat !
Lots of pics now lol
20/3/11
Got few things done over this weekend and found my camera so pics are much better
Got the immobiliser fitted so that ment I could fit the dash and try the cage for clearance:
Now much to my annoyance the cage didnt fit, I thought I had moved it back as far as would be needed, I lined the main hoop up level with the door shuts thinking that it would be fine, but on fitting the front half of the cage it was aparant that I should of fitted it a good 1/2" further back.
You can see where its touching the dash:
So had no option really but to cut the dash to make enough room, Didnt want to start cutting and rewelding the cage.
With that, I bolted the cage in, which was a ballache of a job on my own but got there in the end.
Heater panel refitted and connected also in this pic
Spot the schoolboy error in this pic lol
Bolted into the B pillars too:
Rear view with the extra strut bar I made:
So thats the cage sorted, just need to order a few more allen head bolts to finish it off, Will fit the door bars last of all.
On to a few other jobs,
Made a bracket to fit a corsa C header tank:
Like so:
Main power junction box:
Astra mk3 main fuse box, for Ecu, car and EPAS:
Battery tray bolted into the spare wheel well:
Harness eye bolts fitted:
And corsa C abs sensor fitted and wired up to work the electric speedo clocks:
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vauxhead
Member
Registered: 9th Oct 10
Location: Liverpool
User status: Offline
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2/4/11
Set about running the main battery wires, P clipped it as neat as I could, all the way to the junction box on the bulkhead:
Then on to fixing the seatbelt eye bolts into the tunnel, the rivets are purely there to hold the FIA spreader plates on, whilst the bolt is tightened up
Got a fire extinguisher too:
So seats and harnesses are all in and sorted:
Next job is to find somewhere to put the ECU`s:
Not alot of room really :doh:
22/4/11
Got the exhaust system on, just a pic of the back box
Connected up the EPAS Ecu:
Viewed from the seat:
Bought a colour coded rear bumper and debaged grill:
Need to find a front bumper now
Then on to the gear box, drilled and tapped the 3 holes for the rear mount and modified the gear linkage:
Will replace the plastic link with a metal one, just need some 8mm threaded bar.
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vauxhead
Member
Registered: 9th Oct 10
Location: Liverpool
User status: Offline
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Bit of a delay in progress basically nothing happened throughout May, will explain why when I get to the engine.
6/6/11
A small update but a highly significant one, billet steel lightweight flywheel arrived this morning which means the engine can finally go in !
8/6/11
Engine and box as one, started to fit the ancillaries too:
Filled the mounts with window bond to beef them up a bit:
Not far off now!
11/6/11
The project was orginally a joint project with my friend Vickky who rebuilt and supplied the engine, she did buy it to fit to her mk3 astra but broke the car instead.
So we decided to build this corsa to have a bit fun with, the deal being I was to do all the work and buy the stuff for the shell, she was to buy everything to do with the engine.
Needless to say, the plan didnt work out 
Engine in!
It fought us all the way though, went in from underneath in the end as there was no way it was gonna go in from the top.
Next jobs are to buy the water and boost pipes, fit the oil cooler and intercooler, tidy all the wiring, fit the shafts and buy some brakes
22/6/11
Working the way though all the jobs needed to get everything fitted now.
Made a bracket for the weber fuel reg and welded it to bulkhead bracket for the old header tank:
Only needed to cut the union off the return pipe to connect it too the reg, the feed went straight on to the fuel rail.
Gear linkage fitted and plastic link arm replaced with metal:
Ran the crank sensor and coolant sensor wiring neat and looking at the alternator clearance, glad I bought a 5 rib ali pulley now tho lol
New alloy one way breather valve:
And box of fluids donated from work:
More soon !
[Edited on 01-01-2012 by vauxhead]
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gidged500
Premium Member
Registered: 18th Aug 09
Location: Lancashire
User status: Offline
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looking good keep up the hard work !
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vauxhead
Member
Registered: 9th Oct 10
Location: Liverpool
User status: Offline
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1/7/11
£150 worth of hoses turned up whilst I was away on holiday, got back today so got on with fitting them
Green wasnt my idea btw
Sadly the smaller heater matrix pipe is no good due to using the astra plastic pipe so will have to buy one of those metal ones :doh:
Had to chop the slam panel a bit to get the turbo intake pipe to fit:
Bottom hose, never worked put why this hose on corsa`s is half way up the rad though ?
Top hose:
And intercooler bolted on to the brackets Ive welded on.
Need to find room for the oil cooler, but will probly end up buying another narrower one .
2/7/11
Did a bit more today:
Got the heater matrix pipes sorted, ended up using a mk3 astra one in the end for one of them
Had to cut one of the metal matrix pipes down to get clearance for the inlet manifold tho:
Intercooler from underneath:
Front suspension and equal length shaft fitted, going to have to shorten the passenger driveshaft by about 15mm
Dash pic:
Bumper on showing the intercooler with the numberplate on for road use:
And taken off for track use, going to paint the cooler black and chop a little more bumper off then get it painted:
Waiting on boost hoses now...
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vauxhead
Member
Registered: 9th Oct 10
Location: Liverpool
User status: Offline
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5/7/11
Drive shaft modification:
Some say that big block shafts fit with no messing about, but all cars have "tolerances", The equal length shaft fitted fine, the passenger side did not.
This is what I found when I first fitted it :doh:
The trick to get the short shaft to fit is to create new circlip grooves to allow the shaft to fit further into the cv joint, effectively making it shorter.
So strip the short shaft of its cv boots and joints then clean:
Said circlip grooves:
Find that a 1mm cut off disc is the perfectish size to cut a new groove:
Come up with a novel way of securing your cut off tool to your work bench:
Attack driveshaft and carefully cut a new groove at either end, step back and admire your handy work, thinking I couldnt do better even if I had a lathe
Try in CV joint to see the difference:
And the end result being that the shaft is now about 12mm shorter the ball joint fits:
10/7/11
got the oil cooler fitted:
But now have an issue with the wheel catching the pipes on full lock, which is down to the pipes and cooler being 5/8bsp instead of 1/2bsp so Im gonna have to sort something out with them :doh:
And fitted the old brakes off my GSi for now.
23/7/11
Had the front bumper painted so fitted that today, painted the intercooler black and fitted the boost pipes properly.
Need a new fuel regulator now though as this weber seems to be stuck on 70psi and theres an oil leak from somewhere
27/7/11
New shoes turned up today, Yoko parada spec 2`s:
And sorted the fuel pressure problem, turned out to be a blockage in the return pipe from the rail to the reg :confused:
7/8/11
Scrubbed up, everything checked, ready for MOT
Now Mot`d
Insured as a 2 litre turbo through www.reis.co.uk
Sent the log book off to declare and tax it as a 2 litre, waiting for that to come back
Drives nice and tight feels good on the road
Epas works spot on and the engine diagnostics too
Unfortunately the oil cooler sprung a leak from its core on the way back from the mot station, new one ordered though.
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Darryl H
Organiser: South Central
Premium Member
Registered: 19th Nov 09
Location: Camberley Drives: Porsche 944
User status: Offline
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Proper little sleeper that!
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DansCorsaSXi
Organiser: Yorkshire
Premium Member
Registered: 13th Jan 10
Location: Worksop
User status: Offline
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Wicked update mate!!
You've made some right progress on this,i love the lime green hoses,goes well with the silver.
Good work with the shafts.
Star silver C20XE SXi Project thread
Smoke Grey Corsa GSi Project thread
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Jed D
Member
Registered: 15th Mar 11
Location: Durham
User status: Offline
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lot of good wrk has gone into this by the looks of it....
very nice.... love how its pretty standard looking aswell
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dannyboy17
Member
Registered: 27th Oct 11
Location: Aylesbury
User status: Offline
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brilliant sleeper, love the green hoses as well
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