djgritt
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Registered: 1st Nov 07
Location: Dorset Drives: Focus ST / Hyundai i20N
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Following on from my 'New Car Day' thread - HERE - I recently purchased a car that I had been wanting for a very long time now - a Monaro.
Although I had always wanted the 6.0 VXR model, the later ones, I missed out on them at their cheapest. After a few chats with a friend who owns one, I had warmed to the idea of looking at the 'base' 5.7 CV8 models as well.
That was when this one was found, the fact it had a lot of choice upgrades, most notably the Supercharger, and that it was up for an extremely good price made it almost impossible to not consider. A deal was done, and here we go.
The Spec on purchase was;
2006 Holden/Vauxhall Monaro CV8
Odyssey Blue
5.7 LS1 V8
Harrop 112 Supercharger/Intercooler - 9psi Boost
Wortec/Powerflow Exhaust System (Wortec centre, Powerflow backboxes)
K&N Panel Filter
LS7 Clutch/Flywheel kit
Ripshifter
AP Racing Brakes - 6piston/363mm Front : 4piston/342mm Rear inc. braided hoses
Pedders 'Low' suspension kit
Pedders Drop Links
Pedders Quickrack kit
Monkfish 'Road Response Pac'
Monkfish 'Rear End Pac'
'Holden Design' rear Spoiler
Monaro VXR style rear light clusters
Sony aftermarket HU
It also has been converted to and the ability to run on LPG. This isn't something I am still decided on - I know little about it, it adds a lot more complexity to the engine bay, and adds a new system to maintain or repair. However, fuel is ~54p p/litre, and this really is hard to ignore.
As it has so much already done, it needs very little doing to it in terms of upgrading things. So, the plan is to tidy a few bits up, add some personal touches, and try to use it as much as possible.
Anyway, a couple of pictures for posterity for the thread - more from collection are in the link at the start;
 IMG_4249 by Dave Gritt, on Flickr
 IMG_4235 by Dave Gritt, on Flickr
 IMG_4228 by Dave Gritt, on Flickr
Within a week, I had removed a bulk of Audio gear that I hadn't bothered photographing previously as it was rather poorly installed - 2x Amps mounted to the support frame of the fuel tank, and a Sub-box loose in the rear footwell, all connected to some poor wiring, plus the normal Phono/Power/Earth cabling.
Upon ripping into it all, I found a few signs of 'questionable' workmanship, some of the OEM Speaker wiring has been cut but these can be resolved in due course - all of the front speakers are currently working so that is good enough for me tbh.
Had to remove some of the trim to get all of the access etc, but thats pretty easy once you find all the screws/clips.
Now though, I have a fully useable boot space! As massive as it is....
A few days after collecting it, I realised I needed to do a test; to make sure it would fit in the Garage.
It just gets through the door with the mirrors tucked in - however, once it's through, there's LOADS of room.
The car also had some quite rubbish 'Supercharged' badges on the wings/dash - I removed them all as well as the 'V8' ones;
Next plan, replace stupid slogan plates and overhaul the Wortec backboxes - possibly getting some different tail pipes for them too.
[Edited on 08-12-2016 by djgritt]
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djgritt
Premium Member
Registered: 1st Nov 07
Location: Dorset Drives: Focus ST / Hyundai i20N
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Lastnight went to a local car meet - 100 or so different things there, mostly ScEnEd out Jap/Euro boxes covered in tacky and/or FB Group stickers.
It got a lot of positive reaction, one of only 2 V8 cars there, the other being some Dodge thing.
Afterwards, went to a quiet retail park to try to get some night photos - forgot my Tripod, so had to rest the camera on things (phone, lens cap, straps etc) to keep it steady on exposure, but they generally came out ok.
 IMG_4264 by Dave Gritt, on Flickr
 IMG_4287 by Dave Gritt, on Flickr
 IMG_4289 by Dave Gritt, on Flickr
 IMG_4294 by Dave Gritt, on Flickr
 IMG_4299 by Dave Gritt, on Flickr
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Ben G
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Registered: 12th Jan 07
Location: Essex
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Love this car  proper thinking out the box type buy. Bored of seeing endless V8 M3's.
Nice work so far. Love the garage aswell!
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BeetleGav
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Registered: 27th Jun 10
Location: lancashire, nelson
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Such a good motor, I keep looking at them myself but I doubt I'd go for one.
The odd badges would annoy me (Holden front vaux rear) the Vauxhall one would have to go.
Think all I'd do is slightly lower it and change the wheels, the ones on it now look too heavy/chunky looking for the car imo
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Ian
Site Administrator
Registered: 28th Aug 99
Location: Liverpool
User status: Online
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Was going to ask your view on the wonky badge on the dash 
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djgritt
Premium Member
Registered: 1st Nov 07
Location: Dorset Drives: Focus ST / Hyundai i20N
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Stuff.
Wortec boxes need a little bit of preparation for fitting of Electric cutouts, and ultimately fitting to the car.
One of two boxes;
Cutout goes on the triangular flanged joint here, sandwich fitment;
Stripped;
The fittings will be replaced with St.Stl versions.
Tailpipes are to be kept, but I may also get a pair of alternatives as 4" Rounds don't particularly float my boat.
Will strip the next box down later this week, then will need to get a pair of valves sorted.
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LukesCorsaSXi
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Registered: 2nd Jan 11
Location: Sheffield
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That is gorgeous. 
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Ste
Premium Member
Registered: 5th Mar 03
Location: Taif, Saudi Arabia
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Classic Redrow garage that!
I would rather lose by a mile because i built my own car, than win by an inch because someone else built it for me.
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djgritt
Premium Member
Registered: 1st Nov 07
Location: Dorset Drives: Focus ST / Hyundai i20N
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This weeks upgrade... Lights that aren't dim candles.
Fitted HID & LEDs today.
Bumper off and looked at options - other owners have run the wiring through the access cap, but this makes their presence obvious as well as a bit untidy IMO. Spotted an alternative possibility though... The large flat space on the housings underside. This tied in nicely with the Ballasts also being able to fit on bodywork below the Headlight.
Drilled a 23mm hole for the wiring entry, and assembled the internals as needed. The exposed connections in the pics were then taped individually and then together to protect them after the pics were taken. Grommet was a lovely snug fit with the 23mm hole....
Tested. Nicely done.
Also, from inside the engine bay, stealthy. Air box sits in the space behind too, where the camera is roughly. Hides it all further!
Repeated on other side. Same layouts etc, very hidden still, moreso due to the battery placement tbh! Also fitted Diadem indicators - those who have seen recent cars of mine may realise that I put these on all of them. Love the finish of them!
All finished. LED sidelights (& Reg Plate lights, but those are a bit dim so may need a change) also fitted.
They are a big big improvement over the standard Halogens... There is scope to upgrade the main beams in the future if desired too, but these seem good enough for now and I am happy with them. Beam cuts off nicely in the projectors, doesn't appear to scatter anywhere and isn't far different to the beams of the Vectra & Mazdas I owned previously with factory Xenons either.
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taylorboosh
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Registered: 3rd Apr 07
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Noice
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djgritt
Premium Member
Registered: 1st Nov 07
Location: Dorset Drives: Focus ST / Hyundai i20N
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Need lots more practice ahead of going full ASBO.
https://youtu.be/lb1giGEySxE
Now, where was that Line Lock kit?....
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VrsTurbo
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Registered: 8th Jun 10
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Shouldn't need a line lock to do burnouts
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djgritt
Premium Member
Registered: 1st Nov 07
Location: Dorset Drives: Focus ST / Hyundai i20N
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quote:
Originally posted by VrsTurbo
Shouldn't need a line lock to do burnouts
This is true, but Line Lock will remove the wear on the APs....
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noshua
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Registered: 19th Nov 08
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Does sound nice!
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Kyle T
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Registered: 11th Sep 04
Location: Selby, North Yorkshire
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Sounds
Lotus Elise 111R
Impreza WRX STi
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djgritt
Premium Member
Registered: 1st Nov 07
Location: Dorset Drives: Focus ST / Hyundai i20N
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Picking up winter grime this weekend, out & about with some friends. Last time it's being used this year, so gave it a wash this morning too.
Also, recently fitted some new fresh smaller plates which are looking far better than the old slogan ones.
 IMG_4349 copy by Dave Gritt, on Flickr
 IMG_4395 copy by Dave Gritt, on Flickr
[Edited on 18-12-2016 by djgritt]
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djgritt
Premium Member
Registered: 1st Nov 07
Location: Dorset Drives: Focus ST / Hyundai i20N
User status: Offline
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This has been laid up since my last post, to avoid the bulk of winter really.
I've done some recent checks on the Supercharger, along with a charger oil change - I was struggling to fully drain it of the old oil, and also wanted to check the Coupler for it's type incase of ever needing a spare, so stripped off the drive mechanism entirely to get the best access and to drain it.
Only issue was that I was doing it in the garage, which has no power yet. LED torches only! Bit of a faff, but all ok.
Also, this weekend, I brought it out for a HSV/Holden meetup at Surrey Rolling Road for a dyno session.
Made good power of 435RWHP (so around 500HP @ Fly), but it does need attention as it has developed a noticeable flat spot - I've been advised to give it a thorough service at least to try to clear this out.
As the days are getting longer though, and it's slowly warming up out there, I intend to get some more maintenance done on it over the coming weeks;
Service
Brake checks - because I've found the hose banjo bolts loose on the APs all round recently! Loose enough to actually be loosing fluid with the brake pedal depressed.
Replacement Coolant hose behind engine
Also, still got to get quotes to bin off the LPG. Haven't used that system for ages now tbh.
[Edited on 15-02-2017 by djgritt]
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Ian
Site Administrator
Registered: 28th Aug 99
Location: Liverpool
User status: Online
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Why do you need a quote to bin off the gas? Just run it out then disconnect everything, the work out what parts have been drilled and replace?
If you need to move the parts on I know a nice V8 Discovery which would benefit from a more modern kit 
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djgritt
Premium Member
Registered: 1st Nov 07
Location: Dorset Drives: Focus ST / Hyundai i20N
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quote:
Originally posted by Ian
Why do you need a quote to bin off the gas? Just run it out then disconnect everything, the work out what parts have been drilled and replace?
If you need to move the parts on I know a nice V8 Discovery which would benefit from a more modern kit
Mainly for the wiring connections that were interrupted (The LPG has it's own ECU), coolant circuit interruptions (Double vaporisers installed) and to hopefully just have nothing missed out.
Removal of the pipes etc isn't an issue, just the niggly bits that someone else can take responsibility for.
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djgritt
Premium Member
Registered: 1st Nov 07
Location: Dorset Drives: Focus ST / Hyundai i20N
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As per last post, have been having issues with the banjo joints on the Brake hoses.
For the first time since buying the car, I got it up on stands with wheels off this weekend to have a good old look round them;
Firstly, the hose was misaligned due to a roadside attempt at stemming the leak in the past, so after giving the bolt/fitting a good clean with a wire brush and some aerosol, I did notice the washers in use are an Alloy/Steel type and not the normal Copper, and therefore may be limited for crushing which won't have helped with making a seal.
I have had bad a experience with brake hydraulics before so was not going to start removing bits and introducing air to the system on this occasion so just realigned the hose and retightened with some 'meaningful effort'...
This seems to have helped though, a lot.
Did the same checks all round, first time I've seen the front brakes in all their largeness.
Used the car over the weekend and the brakes are still dry and I still have a firm pedal. They feel much better now, actually feel like a big brake setup.
But, as this is my Monaro, no update would be the same without a new issue popping up! I have had some resistance in the gear selection, and also 'lost' my clutch on an enthusiastic run on Saturday, and seemingly I'm not the only one - a common fault on a number of LSx powered GM cars and also subject to a technical bulletin for the Corvette with the same Tremec transmission.
Most cases are down to poor Clutch hydraulic fluid, as detailed in this link -
http://rangeracceleration.com/Clutch_Care.html
Fluid should be in good nick with little fouling. Mine on the other hand? Minging;
So another job for this week. MOT is due very soon so need to get it through that before spending much else!
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djgritt
Premium Member
Registered: 1st Nov 07
Location: Dorset Drives: Focus ST / Hyundai i20N
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Tried the method for a fluid change that I linked above, didn't do much to help. So decided to do it properly and carry out a full fluid flush and renewal.
Up we go, need the wooden blocks to make room for a jack... ha;
Anyone who has worked on the Tremec T56 Gearbox that is installed on these will understand that it can be an absolute ball buster to bleed the clutch without any form of remote bleeding device because of a noticeable lack of space between the transmission and body and because the bleed nipple is INSIDE the gearbox with even less room for play as can be seen in this borrowed picture;
So, you cannot get sufficient access to the bleed nipple without either;
{A} HUGE patience and tiny/skinny hands & arms
{B} A special socket from GM (not easy to source in the UK either) which has a bleed line passing through it, or something like that apparently.
{C} removing the gearbox and upgrading the bleed point!
or even a combination of any of those above....
You can buy a very good remote bleeding line for these through the Specialists that frequent these cars, installed with the Box removed (ie at a clutch change), that gives you a nice bleed nipple right up in the engine bay next to the Reservoir. Lovely.
Oh, but of course mine does not have this.... I shouldn't be surprised!
Mine has a crude Nipple extension, that lets it protrude around 1-1.5" outside of the gearbox housing. It's not pretty, it's not the best for access still, but it works, and saves a lot of annoyance! Similar to this from a VXR8 OEM Fitment;
Although not quite as Gucci as the 'proper' remote bleed kit, this worked well enough and allowed me to do the job with a pressure bleeder in pretty much no time atall.
The result was not surprising though - a bulk of grim fluid was expelled;
The pedal feels better and it seems to be releasing better now, but I am still having a few issues with clutch slip and aggressive changes so may need to do it again then let it settle in, which seems a bit abnormal to me - hydraulics shouldn't need much 'settling' time, but we will see - otherwise we may be doing a driveway Clutch & Slave swap in the future, which will be fun...
After the above was done, I took it straight down for it's MOT. After all of my recent issues, I'm glad to report it passed with minimal fuss!
- an exhaust clamp is corroded and needs replacing.
- the two Exhaust flanges under the middle of the car are leaking slightly (not surprising, they smash my driveway when I pull into it every single time...)
- two rubber bushes on suspension arms (NS/OS) are showing signs of deterioration - the only ones I've seen that aren't Poly and I did see their condition so expected this.
They also adjusted my NS Headlight as I told them it was aiming high but had struggled to align it efficiently on my driveway - they checked, adjusted and left it off the paperwork for me.
So, I have a few issues left to address;
- Supercharger very occasionally makes a whirring noise, like a dry bearing. It quietens down with fresh oil inside so may just keep doing changes to get it through the summer then strip it off and rebuild it - we'll see how it progresses, as don't want to end up with the car off the road ahead of some events I'm doing.
- Monitor clutch slip - only happens on full bore acceleration, so is manageable for now. It may improve now I've renewed the fluids if Internet stories are to be believed, though not convinced.
- Gas. Still needs binning. Tempted to DIY it now, shouldn't be too hard! He says....
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djgritt
Premium Member
Registered: 1st Nov 07
Location: Dorset Drives: Focus ST / Hyundai i20N
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Following the last update, I decided that some parts were needed to get the transmission sweet again. So, splurged some money at Monkfish Performance and within a couple of days received a parcel...
Namely;
- Replacement LS7 Clutch (Friction & Pressure plates) - an OEM upgrade over the standard LS1 item, reportedly good for ~600hp. Mine already has one fitted according to paperwork.
- Hydraulic Slave Cylinder - to rule out any issues with the existing item on engaging/releasing the clutch.
- Spigot/Pilot Bearing - common failure item, good practice to change out once the Gearbox is off to allow access. If it fails, can damage Gearbox main shaft etc.
- Remote Bleed Line - as per previous post - will make future life easier!
- Crankshaft Oil Seals (Fr/Rr) - due to evidence of liquid around the bellhousing, if it isn't clutch fluid it could be oil. Crank seal is something that can fail, didn't know which end was right so got both.
- Twin Coolant Hose - this sits at the back of the engine, gets rubbed by Cyl Heads and can fail. Posted in here before somewhere as mine have abrasions. May as well change sooner rather than later!
All of this is not only because it needs doing, but because I need it fixed/reliable to go to Goodwood Festival of Speed - because, handily, the Monaro qualifies for their Performance Parking, so naturally I booked this with my tickets this year....
So, only a few short weeks to get this all done. On a driveway. At weekends only - be reet.
.
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djgritt
Premium Member
Registered: 1st Nov 07
Location: Dorset Drives: Focus ST / Hyundai i20N
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Updates.
This week saw the first major DIY job being undertaken on this... the Clutch renewal.
So, with a plan to carry out the work at my cousins, due to the wider & gated driveway, and the requirement to have 2 people on it (it could stay there on stands if we needed to complete over a couple of days too) I managed to book a couple of days off work to get it done - as mentioned before, it had to be fine before Goodwood at the end of June and also I wanted it available for a good friends wedding this bank holiday weekend.
The car got loaded up with all of the tools I thought I would need, and the parts I had ordered previously - a few more items had been ordered and shipped directly to my Cousin also - were all rammed into the boot, which surprisingly managed pretty well! I had my 2x socket sets, 2x tool bags, parts, 1x 3t trolley jack, 2x stands, pry bars, breaker bars, torch, boots etc all in with a few little spaces left.
Drove the car, gently, for the 25mile journey to Poole, and yes, the old clutch was still not happy, meaning I definitely had to go ahead with the work - bummer 
Got it up on stands all round and set to work. Firstly, we removed the exhaust sections from the Cats back to give more access to the Propshaft and rear of the gearbox. The prop was disconnected and dropped - the centre support bearing is gone, but this will have to wait until another day - we then dismounted all the wiring harness from the gearbox and set to removing it. Some, namely the top, bolts were a nightmare to get to, but after some wriggling and swearing they eventually came out. The worst thing we came across was a connection from a solid pipe to flexi joint for the Clutch hydraulics. It was an absolute arse to get to and disconnect - it was ridiculously tight too and after almost 2hrs of effort on this alone it was finally undone and we could get onto removing the box itself. This was eventually done, and then the bell housing followed finally giving us full access to the clutch and other components. We removed the old stuff, easily, and then as we could see evidence of oil on the plates behind the flywheel this was also removed giving us good access to everything.
We found the installed Spigot/Pilot bearing to be completely shot - ie disintegrated and in pieces - so it was lucky I had bought a replacement. The remains of the old are shown below as well as a new one...
The oil seal was then popped off and a new one pressed in, easily, and the area given a clean up. We then refitted the removed parts and installed the new LS7 Clutch assembly.
The slave cylinder was replaced and the new Remote bleed line installed - this is such a simple but awesome bit of kit - how I managed the previous bleed compared to the ease of this is unknown.... I do need to fabricate a mounting bracket soon for it though.
Everything was then rebuilt, pretty easily compared to removal annoyingly, and then bled until we had a nice pedal.
We did run the car up without the exhaust refitted, and it sounded proper rudey - the neighbours may have disagreed as it was approaching 8.30pm at this point. :LOL:
11hrs after starting, the car was on the ground ready to go. A long and annoying day but still done in one go in the end. The car now has a very nice bitey clutch and can deliver full power through the wheels again - give it a couple of weeks to bed in and I may go out to do some skids now I can...
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djgritt
Premium Member
Registered: 1st Nov 07
Location: Dorset Drives: Focus ST / Hyundai i20N
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As mentioned in a previous post, I had been able to book the Performance & Supercar parking for the Monaro as it qualifies on their list of eligible cars....
A couple of days before and I was due to get the car out to give it a freshen up ahead of FoS. I'm glad I did (kind of...) as I found it to have a fully flat dead battery! That would have ruined my plans at 5.30 on a Saturday morning somewhat, had I not bothered to do this!!
Splurged out another ~£100 on a slightly larger replacement and all was well again. The trip to Goodwood was uneventful and was happily cruising along the A31/M27/A27 whilst pulling in a staggering average of 24mpg - I even got it up to 53.8mpg whilst going down a slight decline... frugal.
Parked up at Goodwood. Performance parking is publically accessible and behind the Ticketing wall, so anyone in the event can go around there. Mine was the ONLY Monaro in there too over the two days I visited (Friday/Saturday), unsurprisingly.
Surrounded by some very exclusive cars too, even 2x Mclaren Mercedes SLRs, a handful of Aventador SVs etc etc. I felt a bit out of place...
Even got spotted by a fellow owner/visitor and posted on the FB group.
As summer is busy, the next event was immediately after Goodwood FOS - the VBOA National Rally in Market Harborough.
Before I left, I gave the car a deep clean and polish, and loaded it up with the club gear I have at hand, which somehow dented the load carrying capability of the car somewhat.....
The weekend then started with me doing my usual routine in this car and then making my way to meet another Admin member at Milton Keynes - where upon almost arriving without a hitch, there was a loud bang and a slapping noise at low revs... fearing the worst, the bonnet was lifted to find it was 'only' a shredded Supercharger drive belt.
A quick call was made to the UKs specialist for the Holden models, Monkfish Performance, who only happened to be ~8 miles away from my position at the time thankfully, and they had one in stock! That was promptly purchased, and I cut the remains of the old belt off and made my way up to the VBOA venue. With ~150hp less than normal - slow! :LOL: Luckily, the GF later appeared in the Abarth to supplement the power deficit.
I then spent and hour or so the next morning with some assistance from the others on site to get the new belt on - it was a proper pig of a job due to a lack of space and a tight fitting belt! Needed the engine turning over by hand to help drive it onto the pulleys.
Paired up with a friends VXR, the guy who helped me find this one.
 IMG_8814 by Dave Gritt, on Flickr
Since the VBOA weekend, there has been some rubbish news however - Monkfish Performance who have helped with this car for years now (with prev owners) are going to cease trading at the end of the month - so, I've had to buy some parts which need sorting whilst I can;
Propshaft Bearing
Battery Clamps
Floormat retainers :LOL:
I also ordered a shiny Mishimoto large capacity alloy radiator, but they didn't actually have stock and aren't ordering in new items, so I've lucked out and will need to find another supplier for it.
It also needs some changes though. Needs some nicer wheels and a few visual tweaks/tidy ups. It looks a little boring
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tom130691
Premium Member
Registered: 13th Sep 08
Location: Daventry
User status: Offline
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You can buy direct from Mishimoto, got my catchtank from them,
the website tends to pop up 5% of codes if you check out with in 5/10mins aswell
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