dale87
Member
Registered: 19th Feb 06
Location: West Mids :)
User status: Offline
|
Been planning to build a gsi turbo for a few years now and i've finally decided to pull my finger out this year and get it done so decided to make a project thread of the progress I make, not sure on how long it'll take though.
Back in June I bought a crash damaged cavalier turbo for the c20let engine and f28 box. The engine was running standard spec and ran like a dream so I set about removing it.
The cav
The heart of the beast
The pikey engine removal went full steam ahead
Then last week I noticed a clean smoke grey gsi on ebay with engine trouble and faulty drivers seat so put in a last min bid and won it for the grand sum of £510.
Pics from the ebay auction
Turned out to be a very very clean example with EVERY piece of service history/invoices from 1994 and every tax disc and even still on the dealer plates. Also with having only 2 owners from new its totally standard apart from scorpion cat back and cobra alarm and an alpine head unit very pleased indeed
Ill post progress as and when it happens, not sure on how quick it will happen all depends on time and money as always.
[Edited on 05-04-2011 by dale87]
[Edited on 09-02-2014 by dale87]
|
dale87
Member
Registered: 19th Feb 06
Location: West Mids :)
User status: Offline
|
I was warned that the gsi might not make it home and a trailer may be required so armed with my breakdown cover I went to fetch it.
After being on the motorway for 10 mins the car felt very underpowered and was struggleing to do 70 so I decided the car wasn't going to make it, and the fact I was spitting 4 foot flames out the exhaust every time I planted the throttle 
On hard shoulder
And finally home sweet home at 11:30pm
[Edited on 14-02-2011 by dale87]
|
dale87
Member
Registered: 19th Feb 06
Location: West Mids :)
User status: Offline
|
Between buying the engine and the gsi I had been making progrees on freshening up the c20let ready for the transplant, not bothered about going crazy on a full rebuild in a kind of a "why fix whats not broken" kind of attitude.
Turbo and Inlet removed I then degreased and painted the block in good old red hammerite
Degreased the f28 ready for the f20 speedo ring and pick up to be fitted
[Edited on 14-02-2011 by dale87]
|
DansCorsaSXi
Organiser: Yorkshire
Premium Member
Registered: 13th Jan 10
Location: Worksop
User status: Offline
|
Enjoyed reading that,really good start to a thread  That GSi does look really clean,can't wait to see engine in dude,keep up the good work 
Star silver C20XE SXi Project thread
Smoke Grey Corsa GSi Project thread
|
dale87
Member
Registered: 19th Feb 06
Location: West Mids :)
User status: Offline
|
The corsa will be backed into my parents garage for the conversion so I won't have that much access to the rear end of the car so I decided to fit the rear suspension and the rear wheels now so all the work is on the front end.
Rear ap coilovers with the height adjusters left in but wound all the way down
And my 15 inch compomotive mo's with 195/45/15 toyo tyres, sits exactly how I want it too. Also I know about the L piece, I caught it with the jack which wouldn't come out after lowering lol 
[Edited on 14-02-2011 by dale87]
|
Ian W
Member
Registered: 8th Nov 03
Location: Wirral, Merseyside
User status: Offline
|
Looks like a nice example, bargain price aswell
Might buy one myself for the eventual project im going to want rather than wait for them to hit 2k for a clean one !
|
12valver
Member
Registered: 2nd Oct 07
Location: Luton
User status: Offline
|
Car looks really tidy and the compomotives look awesome ! Interested to know what the AP coilovers are like, saw them in total vauxhall this month, and thinking of getting a set...
|
dale87
Member
Registered: 19th Feb 06
Location: West Mids :)
User status: Offline
|
The comps and suspension are off my c20xe corsa, which im slowly stealing bits from for this build (including some reyland 4 pots) then selling the xe'd corsa to help pay for this this project.
I went from fk coilovers to the AP's and I find them way better than the fk's in every aspect and my xe'd corsa felt alot more grippy at the rear with the AP coilovers.
|
Psychotic
Member
Registered: 17th Aug 10
Location: Cardiff
User status: Offline
|
alloys are real nice
|
flybikeslee
Member
Registered: 2nd Jan 07
Location: Liverpool
User status: Offline
|
nice start
|
dale87
Member
Registered: 19th Feb 06
Location: West Mids :)
User status: Offline
|
Put the gsi into my parents garage where the conversion will take place, should hopefully start ripping the c16xe out this weekend.
pic before I start taking the 1.6 out.
 headlights lent to danny90 for his mot as he has lhd fk's lol
And pics of the c16xe saying its goodbyes.
[Edited on 14-02-2011 by dale87]
|
12valver
Member
Registered: 2nd Oct 07
Location: Luton
User status: Offline
|
quote:
Originally posted by dale87
The comps and suspension are off my c20xe corsa, which im slowly stealing bits from for this build (including some reyland 4 pots) then selling the xe'd corsa to help pay for this this project.
I went from fk coilovers to the AP's and I find them way better than the fk's in every aspect and my xe'd corsa felt alot more grippy at the rear with the AP coilovers.
Sounds like the cars going to go like stink  ! Might have to get those AP coilovers, they seem to look much better quality than the majority do, and with your comments it definately sways me to buying them. Will keep an eye on your updates, and like i said on your engine forsale thread, i may be interested in the head if you end up splitting it.
|
dale87
Member
Registered: 19th Feb 06
Location: West Mids :)
User status: Offline
|
Got my log books back for the gsi today, new style red thing never seen them before. Only had 2 owners and the first owner had it for 12 years which explains the full vauxhall history untill 2006.
|
danny90
Member
Registered: 13th Sep 10
Location: tipton west mids drives: corsa 1.6
User status: Offline
|
ha ha the head lights dun the trick dale lol guna see if i can sell the clear depo left hand drive 1ns on here they luk good tho
and ya project is cumin on fast i can remember us tekin the engine out the cav was a laff haha
|
dale87
Member
Registered: 19th Feb 06
Location: West Mids :)
User status: Offline
|
Had a little bit of progress this weekend.
First I got rid of the sound proofing from the bonnet, nice and clean underneath which is niceto see.
Then out came the engine. All the sound proofing was removed from the bay too.
found some rust in the bay, far from rotten though.
[Edited on 14-02-2011 by dale87]
|
dale87
Member
Registered: 19th Feb 06
Location: West Mids :)
User status: Offline
|
After loads of thought I've decided to remove the power steering set-up and go for billy basic manual steering rack for the simplicity. I'll probably regret it on the first car park I come to but this car isn't being built to go slow so it should be better suited to it's purpose imo.
I found a new genuine GM manual rack for decent money so that kind of swayed me too 
Picture of my shiny new steering rack which arrived this morning
[Edited on 14-02-2011 by dale87]
|
dale87
Member
Registered: 19th Feb 06
Location: West Mids :)
User status: Offline
|
Had a chance to wok on the car today so I changed the speedo ring in the f28 box so it reads correctly on 140mph clocks.
One F28 gearbox.
There's 19 13mm bolts to remove in order to split the box casing. Bolts removed.
Turn the box over and removed the release bearing and clutch arm.
Now the casing should split in half and pull over the input shaft like so.
Few shots of my bearings which look perfect to me saying the box was on 113k before removed.
Diff removed. The blue bit is the bit that needs changing.
I chopped the old blue speedo ring of with a hammer and a tough wallpaper scraper.
Then I put my brand new F20 speedo ring in boiling hot water to make it less brittle and more flexible then popped it over the diff bearings making sure it sits right in the groove on the diff.
Then came the hard part, putting it back together. I used some locktite flange sealant I had lying about to stop any leaks, should be ok.
No pics of it back together but was a pig of a job lining all the parts up but got there in the end. I'd already had the 3 rear mount holes drilled and tapped so just got to fit my 2wd conversion kit, F20 cable drive and rear mount spacers then it's all ready to be fitted into my corsa.
I'll update when I next get chance to do some work on it, thanks.
[Edited on 14-02-2011 by dale87]
|
MarkSport
Member
Registered: 22nd May 09
User status: Offline
|
watching this
|
ecclesturbo
Member
Registered: 6th Jan 08
Location: staffordshire
User status: Offline
|
dale still have the cav by chance,good work on the corsa
|
dale87
Member
Registered: 19th Feb 06
Location: West Mids :)
User status: Offline
|
Cheers for the comments.
I ended up scrapping the cav.
It had been crashed on the front drivers side then left sitting for 6 years. It had various break in attemps resulting in it being left with no rear quarter glass and bent doors etc so the interior was virtually destroyed by rain, mold, rats etc cats had even moved in and there was about half inch of cat hairs on the parcel shelf
The engine ran perfect even the 4x4 worked. The car was still drivable, not safe by any means but drivable. I sold what I could from it then just weighed it in.
Shame really because the crash damage wasn't too bad so if it wasn't for the interior and rust problems i'd probably have kept it and restored it.
|
Kieran
Premium Member
Registered: 12th Sep 08
Location: Kent
User status: Offline
|
Glad the speedo thingy works bud. 
Good work!
|
dale87
Member
Registered: 19th Feb 06
Location: West Mids :)
User status: Offline
|
Yep big thanks to kizzacorsab for sorting me out with the bit that drives the cable from a F20. I'd buy anything off this fella his customer service is excellent lol, top man!
|
Kieran
Premium Member
Registered: 12th Sep 08
Location: Kent
User status: Offline
|
No probs matey anytime. glad it got to you ok. Keep it updated bud
|
dale87
Member
Registered: 19th Feb 06
Location: West Mids :)
User status: Offline
|
Update!
Had some more progress this week. I've been tackling some of the rust on the low impact areas and under the arches on the gsi. Not gone mad on it just wire brushed all the rust off with a drill attachment then my plan is to use hammerite no1 rust beater, then spray stonechip on all the low areas and arches then plaster underneath in black hammerite mainly because the engine is out and I may as well do something to tidy it all up while access is easy.
Before pics!
Crossmember.
Under arch.
During pics!
only have pics of drivers arch for some reason
Then after 2 coats of hammerite no1 rust beater, comes in beige or a lovely dog poo brown colour.
Crossmember.
Drivers arch.
Passenger arch.
Just waiting on my chassis strengthening kit to arrive then I can get my mate to weld them in for meand I can finish of painting it up.
More updates tommorrow hopefully. cheers.
[Edited on 14-02-2011 by dale87]
|
jamied
Member
Registered: 27th Oct 03
Location: Marbella,Spain Drives: C63
User status: Offline
|
Great project mate and great updates
|
