dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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another update I've been a busy boy today got my tie bars done, ground the shoulder down by 15mm
then the OCD kicked in so I had to strip them back
then a fresh coat of smooth hamerite to finish them off, these are now ready to swap with the ones on the car now when I take the engine out in the next couple of weeks
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Right update time, have been busy with work lately so have only just been able to get anything done, so made a start on finishing my second inlet as my TIG welder gave up on me so had to give my one to a customer, here's a few pics will be getting it sand and bead blasted very shortly
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Alright time for an update, been really busy with work lately, and other bits and bobs for other peoples cars so haven't had a lot of time for my own lately, but have been buying a few bits
equal length drive shaft, X20XEV coil pack, CTS and some V6 throttle bodie gaskets
also bought myself a new gearbox as the one I'm running at the moment has a few problems in that it hasn't got a diff and the large diff bearing has gone and it isn't mechanical, so after pricing up a new quaife with all bearings etc I found this for only a hundred odd quid more, it has a receipt from Regal for £2000 for supply and fit Quaife ATB with all new bearings, syncros and a full rebuild so basically a new box 
Only problem had a small bit of the casing missing, not a problem, I just quickly welded a new bit in
and then ground it back, will do ain't gotta be perfect
then I had to paint it cause I'm a sucker for making stuff look good :cry:
will give it a final coat tomorrow
also got my new inlet back from the sandblasters has come up really nice will give it a coat of clear lacquer to stop it getting dirty
just need to get my arse in gear and get the old engine out now
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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As usual I've been far to busy to be working on my car, what with doing inlets and re flanges etc but have managed to treat myself to a few bits, first up was a new engine stand 450kg for less than £50 delivered which I thought was a bargin
and then a sandblasting cabinet for £125 delivered which is another bargin as I was being charged £45 for an inlet to be blasted so already it has paid for itself as I've done 3 inlets this weekend just gone Can't believe I haven't bought one sooner to be honest, might make a better pick up pipe for it as the one with it only sucks from one end
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Well thought i'd do a bit of an update as its been a while :cry:
Been busy with work and other peoples projects so only small bit done to mine, started off buying a set of 4 yokohama A034's 195/50/R16's with 5mm tread for a bargin price of £80 :clap: he clearly didnt have a clue what he was selling  msl:
Other things bought were a set of 6 pot WP pro brake kit, came with 288mm discs but were cracked between some of the holes so am looking to get some 310mm or simular from AP racing as it's only down the road from me and Rich has a couple of mates who work there, so he's managed to get me a free health check on the test rig :thumb:
I then spent the weekend before i went to America removing the engine out of my car with the help of Rich and Matt gay Williams so that they could have it for there car, it was an epic of a weekend stripping down 4 corsa's in total for parts etc 
What a prick msl:
and the chuckle brothers in action
Bought some more manifold bits from Browney to replace the ones i used on Robs car ( you still owe me seaman ) 
And then got another bargin in a pair of Supertrapp 544-3003 bolt on exhaust silencers for £76 delivered :clap: these are about £125 each from Demon Tweeks and one has never been used and the other only once
I was really impressed by the supertrapp when i seen it in use on Chip's car at Castle Coombe, it really reduced the db's of the exhaust bringing it under the strict noise limit :thumb:
So jobs to do before i put my new engine in is too remove top part of the bulk head for better access, remove ABS pump and brake lines, fit new brake lines and top mounts, need this done before i move units at the begining of October, which gives me about 2 1/2-3 weeks once i get back off summer leave so need to get my finger out really msl:
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Few bits bought over the months:
Carlton oil cooler
And some bonnet lifters, also some free Saab equal length shafts, need a clean up but have good joints, drivers side is too short for a Vauxhall but passenger side is the same I think, so may use the joints as spares
The Saab units have a better end than the Vauxhall ones as they have a pinch nut and no split pin
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Bored at work today so decided to make myself an alloy radiator, had a newish diesel one so decided to chop it up, the inlets/outlets are in different places but that don't matter, length wise the 16v is about 20mm longer, this is the diesel one
But the core of the diesel is 5mm thicker as you can see
So I chopped the ends off and cleaned it up
I then made an end piece and welded it together, not the nicest to weld 
Will make the other side tomorrow and hopefully presures test it for leaks
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Had a little laugh at myself for being a nob and not checking that the radiator is an actual 16v one, well it's not I can't remember what it's off as when I popped the bonnet on the corsa I thought how small the one in it looked and when I offered the diesel one up it was already a lot bigger with only one end cap on :cry:
The "REAL" 16v one is 60cm total length and the diesel with only one end cap on is 71cm, so with another end cap on will be 76cm and would fit in the bay but there would be no way I could fit my boost piping either side, and there's no way I'm re doing all that so will keep the end caps and buy a 16v radiator and do the same to that one
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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On a slightly better note I've finished my newest design inlet manifold, but sad thing is it's sold already so need to make another one for me :cry:
And once it's been sand blasted
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Had a good few sessions on the car lately and has made me find some much needed motivation to get it done, first off was to reassemble the engine ancillaries and put the flywheel, clutch and gearbox back on
Then decided to beef up the rear gearbox mount as I have the two bolt one and have seen them snap the gearbox casing so made up a strengthening plate
And then painted it and fitted it back on
Since the moment I put the engine in the first time I wished I'd ditched the ABS (I didn't last time as I was in a rush to get it ready for PVS), so this time I removed it fully, amazing how much the bad boy weighed, will re do all the brake lines at a later date when I have more time.
Here's my weight saving efforts for the day
I then set about the engine bay with the angle grinder as I have always wanted to remove the upper part of the bulk head as it's always just got in my way when trying to get around the back of the engine so I chopped it all out an re sealed along the edge
All that was left to do was give it a lick of paint, was only gonna do the bit I'd exposed but ended up doing 3/4's of the bay msl:
Still have ABS wiring loom and sensor wires to remove but can do that at a later date as I need to get the engine in tomorrow as I'm moving units down to Plymouth so need it in ASAP :cry:
Here she sits waiting for her new home, treated her to a touch up paint as some bits weren't as I wanted, as I like things to look new and clean when they go on my car :clap: probably OCD :help:
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Well the good news is that the engine is in :clap:
and all back on the ground just need to put the brakes back on and fit the driveshafts before i move it down to Plymouth
Need to get the rocker cover and belt cover power coated white as i'm not a fan of the black in a black bay look
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Managed to trial fit the brakes, need some spacers but should be alright
Want to get the 310mm discs as the 288mm discs are cracking in places :cry:
Also collected my GRP seats bought them on a whim for a bargin price of £51
All hooked up to the Calibra ready to be to towed down to Plymouth, note to self do not go over the mores again towing a car with a car with shut brakes :cry:
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Small update really, spent a few hours doing little jobs, first up was to remove the ABS wiring loom and sensors and just have a tidy up in the bay and fit bits and bobs like speedo cable and oil pressure sensor and sorting the power distrabution block and alarm, also welded a bolt to the bulkhead to bolt the earths to
then made a alloy plate to cover the pollen filter as i've removed the upper bulkhead so didn't want to use the big plastic cover to protect it from rain
re fitted the scuttle pannel and wiper so job done, just need to mount the header tank and i'm pretty much done with the shitty jobs
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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update time, had to make some spacers for the brake calipers to fit so gave them a quick coat of paint and fitted them
wheels fouled on the calipers so have spaced them for now with what spacers i have but could do with some 10mm ones as i don't want to grind the caliper back as there isn't a lot of meat to take off still need to get some new discs so will no doubt be going down the MG discs that Reyland use and use the lathe to turn the centres out and possibly turn down my bells too to get them sat nice
Found these in my workshop, look way better on my car than Rob's don't you think? msl:
as you can see i've cut my slam panel for easyer access to the turbo etc, i also made a start on my exhaust manifold, as i found out using the larger 42id pipe is a lot harder than using the 38id pipe as all your angles have to be tighter if you want to even get it close to a T3 flange :cry:
First up measured where my turbo (T3/T4) sat and tacked the flange in place so that i can build up from it, reason i've done this is for two reasons, reason 1 is that i can use my existing downpipe and not affect my boost pipes and reason 2 is that i had Rob's GT30 in the workshop and i am planning an upgrade to that in the near future so trial fitted that on the flange as well so that when i swap turbos in the future i don't have to re make the manifold, all i'll have to do is swap the flanges on my down pipe so will be a near enough straight swap
Then started the collector, this was a pain in the arse as i only had a angle grinder to cut and shape them, would of been so much easyer with a band saw as i could of made a jig up and got the same cut ever time
Gave them a quick tack and then welded them together, inside and out as i don't want it cracking
Half way through and the tig welder decided it didn't want to let me have the collet back and snaped of inside :hammer:
So with much swearing i attacked it with a drill and removed the bastard
So finished off and this is how it stands for tonight
Outside done and base flattened ready for welding to the T3 flange, will also use the die grinder inside to neaten it up a bit as it was really tight with the torch, could do with getting a smaller one really
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Continued on the manifold today, hardest part was working out which way to route the runners as you may get one to fit but then not get the other to run past, don't help as i bought the larger 42id pipe :frown:
Here's what i came up with
all tacked up and ready for welding
have to remove runners to allow better access to weld the joints, could of done with a lot smaller tig torch as i really struggled to get in between the runners to weld them
all welded up just need to add the wastegate pipe and tap the flange for the bolts and die grind the ports fully smooth
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Right then busy day again today, finishing off the manifold, first of all tapped out the T3 flange so i could fit some studs in as there is no chance of getting a nut on top
then cut the hole out for the external wastegate pipe, took seconds with the plasma, god i love that machine like a hot knife through butter :love2:
seemed to fit perfect
only once it was on the car, my T3/T4 turbo fitted perfect with the wastegate and screamer but then i realised the GT30 has a 1" larger inlet so would of been way too tight and also didn't leave me hardly any room for a radiator :cry: so had to nick the bit i used to do Rob's screamer pipe, as it was the only way i could mount the wastegate and screamer without it causing me massive space problems
GT30 Fitted, and fine for clearances
took it apart again to weld up all the joints and then finally welded it all together, finished article
Note to self: get tig welder serviced as it has an intermitant fault with the HF :cry:
Back on the car my turbo (T3/T4) temp bolted up, wastegate and screamer on and boost pipe just so i was 100% it all fitted up
All thats left to do is finish off smoothing in the ports as i only had a air drill with a carbide bit in and it don't spin fast enough so will see if one of the lads has got a die grinder i can borrow, not bad for two days work and a massive boost for my car building motivation
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Todays efforts involved check fitting things and a general tidy up, first of all was to secure the removeable slam panel, this is what i came up with
I bolted it to the outer slam and the inner is held in place with riv nuts so is quickly removeable, while i was at it i used riv nuts on the head lamp and bumper fittings as well, next job was to check fit the radiator and fan, fits in nice but has been pushed forward by about 2cm so will need to remake the intercooler brackets and extended the thermostat neck as my pipe no longer reaches, but no great dramas there, also had a tidy up as i was never happy with the paint on the slam panel as it was the standard polar white and looked cream against the glasier white exterior, so painted it matt black (only thing i had) and i actually quite like it
Masked up Vauxsport style
All together and the eagle eyed will have noticed i swapped my chrome spark plug cover for a plastic one and painted that as well, just need to find my white Vauxsport sticker and that will finish it off nicely
Also made a bracket for my catch tank to attach to and secured it with jubilee clips, and used parts of the breath hose i had
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Only a small update, have ordered some V clamps for my exhaust so i can split it down easyer, and ordered a new radiator as the old one leaked out of the end cap
then set about it with the angle grinder to remove all the lugs etc as it doesn't sit in the original place and i need all the space i can get
then decided to fix my fan that i snapped when i shut my bonnet when i first built it and the bonnet check hit it and snapped it so it's been glued ever since
so i cut a strip of alloy and drilled and pop rivited it and it's as good as new, also couldn't resist giving it a quick lick of paint
and all fitted up and ready to go, you can see how battered the old one looks
other jobs done today were removing the manifold again and die grinded the ports and perminently fitted the the studs for the turbo
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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done some more nit picky jobs today, first off was to face the manifold flange, and fit it, but then realised i couldn't do all the bolts up so off it came again, had to remove the heat shield so i could get a spanner down the back, a right pain in the arse :cry:
Then realised i'd not fitted the thermostat housing on, and had visions of it not fitting and having to take the manifold off again, but a quick change of bolts to hex heads insted of allen key and it was on, only after i cleaned it up with the sand blaster
then fitted a new CTS sensor for good measure. While i was in the cleaning mood i decided to dig out my alloy oil cap and give it a quick buff
Fitted the turbo on and had dramas with that as well as i couldn't get behind it to do 2 nuts up so had to remove the oil breather pipe and cut down an old 19mm spanner to get in the tight space :cry:
While it was off i used the OA kit to bend the breather pipe slightly as i had to twist the connection on the rocker cover to get the manifold to clear and it was to close to call so bent it out about 5mm to stop the silicon touching
Added some heat shield to be on the safe side
Final shitty job for the day was to cut down the tie bar bolts that go through the crossmember as they were touching the boost pipes and didn't want them to rub through, and gave it a lick of paint ready for the radiator to be fitted
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Todays efforts was to shorten the screamer pipe by about 90mm as it now hung too low and permanently bolt it up, also fitted all the intake pipes to the turbo and fit the air filter in it's old place behind the fog light hole. Then fitted the radiator, managed to get it in without smashing the shit out of the fins so i'm happy
Had to extend the hose on the thermostat side as it no longer reached, and then wrapped it in heat wrap to stop it melting next to the manifold, god i hate that stuff was itching for the rest of the day :cry:
Final and most fiddly job was to mount the Carlton oil cooler, this was the only place it can possibly go so after a good bit of trimming the bumper and swapping various oil cooler hoses around i got it to fit nicely and zipped tied in for a solid fit, what would we do without zip ties :dunno:
V clamps turned up today
Had to mod one of them as it didn't come with a cap, so put a quick weld down both sides to stop it spliting when tightening, so cutting the exhaust and fitting them and the intercooler will be a next week job
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Only a small update today, started to make the brackets for the intercooler, had it on the blocks to get it in position to make them, i used 3mm thick duralumin, which is a stronger version of aluminium so was man enough to hold it in place
all in place with the boost pipes re attached, it sits about 2cm further out but i'm not to worried about the looks, it also allows plenty of air to hit the oil cooler below it which is a added bonus
Trial fitted Rob's inlet so i had an idea of the angle the boost pipes will need to go at, also re sprayed the spark plug cover as it was a bit shit in places, the dizzy cap isn't staying i'm going for a coil pack set up
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Small update but an update all the same, i have to keep doing these to keep me motivated
I'm busy making inlets again at the minute but did an hour on my car, seeing as Rob was round i dug out my loom and he told me what the un labeled bits were as i hate electrics and had very little interest in it, but seeing as i'm getting close to getting the engine completed i wanted to make sure all was well, there are a few things that need extending like the TPS, ATS and the coil wires need changing to coil pack, which means i can ditch the ugly looking dizzy and hall sensor block
I've tried to hide as much of the loom as possible and i've trial fitted the vacuums also.
Most important thing of all and clearly the best mod on the car was the addition of the Vauxsport sticker on the spark plug cover :thumb: Looking forward to my White powder coated cover turning up as it'll suit it a lot better
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Piss poor update but one never the less msl:
New white powder coated cover a absolute bargin at £19.50 delivered
Looks so much better than the black one
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Right update time has been a while as i've been busy with work and my spare time has been taken up with doing manifolds, but i have not given up on my car, in fact i've just spunked a fair whack on it this month as Rob Twitchall decided to break his i thought it would be rude not to have some bits off him, so after half a day stripping his car for him this is what i've bought
Various bits
fuel system upgrades
750cc injectors and turbo feeds
And last but not least a Garratt GT3076R
me being me decided to pull it apart and clean it up msl:
Before
After
also couldn't resist grinding the hotside down
and then sand blasting it
all back together and looking like new
on it at the minute is a .63 hotside but am waiting for Rob to find the .82 hotside in his shit tip garage so i can fit that, after i've blasted it of course :help:
Treated myself to a set of these not bad for £140 new delivered, just had to change one of the bolts in them as i wasn't happy how much it could move in the bush so fitted a 9/16 bolt iirc and is now a snug fit so won't cause me issues further down the line
Also bought another big shinny thing but will post that up when it arrives msl:
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
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Had a nice big box turn up today, was trawling ebay one night and spotted mick was splitting his 600bhp Tigra and this was a steal of a price so couldn't turn it down really, i'm currently trying to find a cheap supplier of the plenum part from the states so i can start making up my own so thought this would be a good one to copy from
Is CNC machined and has a 3" throttle bodie
Gonna give it a good clean up of course as i can't stand it being dirty msl: :help:
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