Bealescooby

iTrader: (36)

Looking good mate glad to hear you got to the bottom of the starting issue and got it running

IanPaskin

Little update,

Got some manifold spacers, had these for two reasons one to help stop the heat transfer up into the manifold and the other to raise the manifold so I could get the intercooler pipe under the manifold…



Also got our new TIG welder came on Friday so spent Saturday playing with that took a while to get anything like a decent weld, which still not too pretty…

But then this morning got impatient and had a go at a intercooler pipe, which was a total different game really struggled with positioning coming around the pipe, but managed it… not so pretty though,



Had to chop a couple of lugs where the std fuel lines bolt up. But it fits nice,

IanPaskin

Cheers mate, yeh still can't believe it was just the starter motor...

JonMc

iTrader: (51)

I like the idea of running the intercooler pipe under the inlet and I'm guessing heat won't be an issue as it's pre-cooling but do you intend wrapping it anyway

IanPaskin

Hi Jon, my thought is the heat won't really be an issue within the pipe as it is pre intercooler, and this normally routes back around above the turbo which is arguably hotter, the main heat concern is it transferring up to the manifold so yes it will be wrapped at that section,

Long term I want to rotate the manifold but it's a bit tighter in the Astra as the bonnet started to ramp down a lot more...

IanPaskin

Been doing some more on the intercooler pipework but learning TIG welding on these pipes is probably not a good idea, so I think I will be tacking them together and will get someone else to weld them up,

Then I put the painted bonnet on, and another slight issue the colour match is out, I had to get some more paint mixed and it’s a lot brighter white than the car so I’m going to have to get that re-done, the camera has actually picked it up more that you can see by eye and in the sunlight it would probably be less noticeable, but I think we will be redoing it...



The door handles are also in the brighter white but it’s not as noticeable.

IanPaskin

Had quite a bit of time on the car over the Easter break,

Been busy working through my job list, although I had ordered a fair amount of stuff last week an still waiting for a lot of parts to be delivered,

I’ve done some more on the electrics so this is nearly finished now, which is a big job done,

I got an extinguisher kit form JJC so started to look where that will be mounted and I fitted the pull cable along with a battery cut off pull into the scuttle tray on the passenger side, forgot to take pics !!

The main extinguisher will fit in front of the passenger seat,

As I was waiting for parts I decided to tackle the rear window, after cutting and trimming the Lexan it into shape I fitted rivnuts where I can’t get to tighten the bolts up



Then needed a black border to hide the inside of the tailgate, so masked the shape and cut around the tape with a blade and peeled the protective film off the bit needing paint,





Then painted and fitted, well a few bolts holding it in, some more bolts needed…



I also took the rear bumper back off and painted the diffuser black and fitted the rain light in the middle,





Another job was to swap the rear springs the ones I had are very hard so now changed for some slightly longer and softer springs, and now set the rear ride height a bit higher as it would have rubbed where it was…





Side skirts needed a bit of work cutting the holes for the sill stands to go through, these are now done and ready for paint,

Scooby Stevo

iTrader: (1)

whats the crease in the rear panel? will it get covered by the trim piece ?

IanPaskin

Do you mean the side rear quarter where the White an orange meet?

I put the fuel filler in that panel but it was to low so had to weld back up and skim that panel, yes the side trim will cover it, just need to get them painted...

IanPaskin

Another load of small jobs done, and a few pics from last week,

Cut off pull cables





Modified the battery box as the battery was tight on the body so needed to sit a bit higher and as I had the nice battery clamp from Rallytech I decided to use that and welded some brackets to the side to hold from slipping off…



Put some rivnuts in the body for the exhaust plate to fit on, typically the tool broke on the last one but bolted up for now and new tool on order



Got my bolts and washers for the rear screen, a bit blingy but look good



Then started to work on tiding up the passenger footwell, I did make a tunnel cover to hide the wiring from MDF a while ago never really liked it so decided to make a frame out of alloy angle and will make up some ABS panels to bolt onto it…

Also got a foot rest




Again a few jobs done with no pics…

Modified the Rad removing the old un-needed rad cap and fitting an 8mm tail for the pipe from the header tank,

Clutch hydraulics now done, just need a proper bleed as I was on my own…

New tailgate struts fitted as the old ones were not brilliant…

Hoping to have water in the rad next week...

rentonone

iTrader: (1)

That's a lot of niggly jobs you have tied in there Ian good work!
Just can't wait to see this car in action!

James

JonMc

iTrader: (51)

Some tidy work there Ian - when I get back do you and your welder fancy a holiday in London in exchange for a loan of my rivnut gun

Arch

iTrader: (59)

Ian I would maybe think about some heat protection for the intercooler pipe running under the manifold. I think you will be very surprised just how hot the inlet gets some heat will transfer into the pipe work which will raise the temp, by how much who knows, but this temp then has to be taken out by the intercooler. I have a pipe running under mine, it has an air gap but I also had it ceramic coated. Worth thinking about given its an easy job. Car is looking really good really like this project.

IanPaskin

Cheers James, every time I cross something from the list I seem to add something else,


lol, you still looking at a flat boot floor? maybe up for a mobile welding weekend...


Hi Arch, yes was going to do something... was thinking heat proof sheet as I have some off cuts... but I suppose ceramic coating would be a better option as space is tight,
I'm probably slightly better off to with the Astra as the intake/grille in the bonnet is directly inline with the manifold I know this will pick up some heat from the rad but there is a definite gap above the rad with clear sight of the inlet...


I suppose its going to be trial and error as with a few other things...

IanPaskin

A little update,

Water hoses are now all in place (well except an expansion bottle) including a new set of lower hoses.



Then I got the front lower cross member and headlamp panels sprayed as it was never completed before,

Fitted rad and wired up the fans with some new plugs



Had to knock up some lower headlight supports as the chassis rails are now lower… nothing fancy but they will do the job…



Then a few shots of the front built up…







It’s going to have the intercooler modified and the pipework done on Sunday, I’ve tried to do it myself with the new TIG but not happy with them, so going to someone who knows what they are doing

Then when its back which should be midweek next week I can fill the rad and give it a proper run.

Lastly – I need to get the rear spoiler painted, I was tempted to get a carbon or alloy one but I’m not sure about them so was hoping to see a few at PVS to give me some ideas.

So for now what colour do you think ???

I quite like it white but from some angles looks a bit out of place





did also think about the underside and rear grey and the top/sides orange...

BrownPantsRacing

iTrader: (6)

That's coming along very nicely now. great work!

averyp2

iTrader: (25)

Good progress, nearly there now! Personally looking at the lines I would just stick with black for the spoiler

IanPaskin

Main objective this weekend as I had some other things on was the intercooler pipework, so the car went off to a mate Sev to get the intercooler modified and pipes made up, and he did the fuel filler pipe while it was there putting a filling vent in,
needed an extra 90 bend over the turbo to finish so that’s ordered now and that doesn’t need welding will just couple up with a joiner...

Also managed to get a few other jobs done finished my brake duct back plates done I was going to get them powder coated but now decided I will see how they work and then make some out of Alloy as they have a bit of weight to them, also now have the front discs on the right sides

Didn’t expect to get the car back until Tuesday so planned some home duties in for bank holiday… but I’m off on Friday so will have a full 3 days on it next week…

A few pics from the weekend,

super_ted

iTrader: (30)

Looking really good now, well done.

IanPaskin

Some good progress and looking more and more complete,

Got most of the paint work done on Saturday and now fitted the front bumper and side trims ect

Also finished most of the wiring and had it running again today for around 5 minutes was a little lumpy at first but generally sounded good,

Bled the clutch and tested that which was a relief although with the pedal box there isn’t a great deal of travel so I moved the pivot point which made it better but I may have to make some mods to give more travel as bite point is near the bottom.

There is a little more to do on the wiring but only things like high beam and indicator dash lights ect

Forgot to take my phone with me today so only got a few pics today my lad’s phone by text so not great quality









Just need to wet flat and mop the bumper, also want a splitter but not sure what to get yet so will wait on that for a while.

couple of under bonnet shots, I do have a new header tank on its way from Rally-Tech so the scruffy one will go...









Hoping to go for a spin in it next weekend

beef-on-the-bone

iTrader: (5)

looking good

Infected by sti

iTrader: (6)

Get in there Ian

Looks cracking pal, really enjoyed this build along the way, I hope you have plenty of future mods to keep us reading

rentonone

iTrader: (1)

Looks fantastic mate well done! I bet you can't wait to drive it after all the work you have done.
I can't wait to see it in action!

James

IanPaskin

Cheers...


its far from finished or the way I want it, but I need to get it to a usable point then work out a plan for the extra mods....


yeh looking forward to going up the road in it... you should pop in over the weekend if your about...

IanPaskin

Done a load of small jobs and had the spoiler and side skirts painted, decided to just go white on the spoiler for now, might change at some point, or even a different spoiler…

Most of the underside jobs are done just need to bleed the brakes but I have been on my own most of the weekend and I need 3 people as I have to do a side at a time due to running separate front and rear master cylinders

Also need to do some basic alignment still,

Then some slightly bad news I have a small oil leak I think from the sump but maybe a rocker cover so need to sort that, so I have dried off and will check again in the week…

As usual it’s taking a bit longer than planned but getting there, I wasn’t really sure what to do with the tunnel/electrics cover so I have just made it functional for now although it looks ok,

Also plumbed in the fire extinguisher…







Then a few random shots now its on its wheels…













Slowly but I'm getting there…

scoobysteve

iTrader: (3)

literally just noticed the thread about 2.5 hrs ago, and thats me caught up. absoloutely sensational mate, keep up the good work. so close to the finishing line.

Scooby Stevo

iTrader: (1)

watched this from the start and never thought you'd get it finished - looks quality mate - good work

IanPaskin

cheers mate... glad you enjoyed the read...


tbh there have been a few times its done my head in and I have wondered too if it would ever get finished, but so close now... just need to not rush the last few jobs...

IanPaskin

Took the car round the corner to a mates (Paul CCA) unit today as he was having a BBQ as he has just moved unit, still no prop so just drove it in FWD brake pedal was nearly on the floor but felt good and an achievement…

So now just to get it cleaned and tidied for PVS next week…

Some pics of it with a different background

BrownPantsRacing

iTrader: (6)

Great achievement. Very well done.

Are you keeping it as a 1.2 astra on the logbook?