Ste L
Member
Registered: 3rd Jul 06
Location: Manchester Drives: 106 16v Rallye
User status: Offline
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From the beginning, I have got a cav SRi sat on my drive with lots of goodies on the engine but the body is shot and finally decided I wanted to do something with it.
Monday 6/8/07. So whilst driving to Aberyswyth I asked Namkeaps to have a look for a decent looking corsa shell 10 minutes late I had won one on ebay:
Went to pick it up and was pleasantly surprised at just how good a condition it was in for £170! Also decided to go half's with Namkeaps on the whole project.
The bad bits:
Both doors have been bent back and started to rust on the bends.
Two small (less than 5p) spots of rust on the boot.
A couple of very minor dints.
The good bits:
The 1.2 engine runs well.
The shell its self has no rust what so ever.
The sills look like they have never seen a jack!
A couple more shots:
Tuesday 7/8/07:
Made the first purchase, one of many more to come:
Started stripping the interior out:
Namkeaps managed to smash the windscreen. Bit of a pint in the arse - but not the end of the world lol:
Wednesday 8/8/07:
Ok so we hit our first set back today! On the way home from the unit last night I got a phone call from Namkeaps asking if I could tow his astra off the motorway. Get there and have a quick look, you could roll the car backwards, but wouldn't move forwards and if you tried to drive forwards it would hop and skip and bang alot. So rang the AA who said they would have a flat bed with us after 1.5 hours. So sod that, flew up to work, picked up the trailer and within the hour the astra was back outside Namkeaps house.
Went up after work today to have a look, fearing it was going to be the 4th gearbox in 3 months. Turned out to be the drivers side calliper, the top securing bolt had come out and the bottom one was loose so was sitting against the wheel. Few bolts later and all is right again.
So to days purchases are:
CV's
Strengthening plates
Engine mount kit
And a 2 1/4" Bore Twin Box Ashley Exhaust System .
All courtesy of Chris Astley Motorsport.
Friday 10/8/07:
Out with the old, ready for a good cleaning ready for the welding, underseal and maybe a spot of paint.
New remote control engine crane comes in very hand:
The donor:
Sunday 13/08/07:
Didn't manage to get too much done over the weekend, works van popped its clogs on Friday and also had a few problems with the roll cage, any how picked it up and gave it a trial fit. Finished cleaning out the parts I wanted from the cav, and stuck all the rubbish from the corsa in it.
Only a couple of pictures:
The super hi-off road corsa 
Poor old girl, still sits nice and low:
Monday 14/08/07:
Time to give the interior, bay and underside a clean to see what kind of condition the shell really is in. Amazing what a bit of cleaning can do:
Picked up some bucket seats, corsa subframes and also dug out my old harnesses:
Tuesday 15/08/07:
Today was just the start of the prep work for some welding, painting and fitting of the roll cage:
I now officially hate spot welds the damn things just seem to hold on and on
:confused:
Friday 17/08/07:
Finished removing rear seats brackets to help with mounting the cage, also removed the heater matrix and its controls ready for a switch panel, also stripped the loom of the non essentials like the radios wiring, all the heater controls wiring, boot wiring and finally for today preped it for some of the welding that needs doing.
Looked at a quick rack from Deamon Tweaks thought they would be a bit more exspensive so think I will be ordering one whilst there is plenty of access in the engine bay.
Pics:
Saturday 18/08/07:
Today was mainly aimed at getting the welding done on the interior ready for painting inside and the underside. Got 95% of it done, just got 6 small bits left to weld but ran out of wire just as it was time for the shops to shut :cry:
Incase your wondering why all the sparks, we were using a gas less welder as the big mofo's voltage regulator has packed in so was just blowing holes in the thin steel 
Had one small set back forgot to remove the plastic connecting pipe that sits between the filler cap and the tank, wondered where the 'extra' smoke was appearing from  msl:
Wednesday 22/08/07:
Got all the interior welds cleaned up where needed and gave the floor area a coat of primer ready for a bit of paint.
A few more parts arrived today:
Friday 24/08/07:
Well didn't get what I wanted to do tonight, but on the other hand got alot more done instead was going to concentrate on painting this weekend.
Finished stripping the parts of the cav, suspension, full custom built stainless exhaust system, engine, gearbox, ecu, loom and accelerator cable. Didn't get too many pictures as I was working alone apart from a mate who popped in just in time to finish dropping the engine, not too bad though only too 3 hours 15 minutes:
Stubborn H frame bolt soon changed its mind when the oxyacetylene came out
One of a few reasons why the cav shell has past it, suppose its one of the problems of towing way too much weight and carrying tools and 3ton jacks round in the boot:
Sunday 26/08/07:
First coat of paint on the interior.
Monday 27/08/07:
Finished off painting the interior today. Also Waxoiled/undersealed the underside too. Got the rear suspension sorted too.
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Ludacris Turbo
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Registered: 28th May 04
Location: High Green, Sheffield
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Cool thread! can't wait to see it finished!
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WMCMoo
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Registered: 22nd Sep 06
Location: Rushall, West Midlands
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wicked thread mate, wish i had the time and money to do summat like this ohh and the knowledge lol
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namkeaps
Member
Registered: 25th Jan 06
Location: manchester
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it aint cost us as much as you think. woody@dc had the idea and we discussed it and we are now going halfs on it .... so far i dont think its gone over £1500. mainly due to already having the engine and a couple of other bits which yet we do not want to say what they are
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-wylo-
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Registered: 4th Oct 04
Location: Dunfermline
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Love threads like this. Great progress so far, wish i had enough space and skillz to do this! 
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Nath
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Registered: 3rd Apr 02
Location: MK
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Ace thread!!
Also:
Love it!
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dan_c4rsa
Member
Registered: 12th Dec 06
Location: North Yorks Drives: MK3 Seat Cupra
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i want that crane too 
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P1CK4D
Member
Registered: 19th Jun 06
Location: Around Essex Somewhere
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Looks brilliant! So jealous tho. Would love to have the space and knowledge to do something like this myself!
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Whittie
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Registered: 11th Aug 06
Location: North Wales Drives: BMW, Corsa & Fiat
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Good thread, will be following this one!
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dan_c4rsa
Member
Registered: 12th Dec 06
Location: North Yorks Drives: MK3 Seat Cupra
User status: Offline
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give it a crack 
i did my mk1's nova conversion in like a 5 x 7 metre garage. is so much fun learn as you go!
and as for that warehouse bloody hell i'd be in heaven. good project. take it offroading on those stilts! before you do anything to it!
[Edited on 29-08-2007 by dan_c4rsa]
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Ben ev
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Registered: 23rd Oct 05
Location: kingslynn / torquay
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the universal lambda's are wank. better off pulling a genuine one off something else
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Ste L
Member
Registered: 3rd Jul 06
Location: Manchester Drives: 106 16v Rallye
User status: Offline
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bit of an update..
i bob down tonight to have a nosey and help out..
fitted valver brakes, some wheels, and sanded cage down and primed it..
will post pic's up when woody upload's them
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ChrisBoom
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Registered: 6th Dec 06
Location: Highland
User status: Offline
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How much underseal did it take to do that? Need to underseal mine soon, bought 5 litres, think that might be enough
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Ste L
Member
Registered: 3rd Jul 06
Location: Manchester Drives: 106 16v Rallye
User status: Offline
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5 litre's should cover it i guess lol..
could do with getting around to doing my own corsa
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ChrisBoom
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Registered: 6th Dec 06
Location: Highland
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quote:
Originally posted by Ste L
5 litre's should cover it i guess lol..
could do with getting around to doing my own corsa
Haha, thats good then.
Take it you had it up on the ramp for the underside? Need to wait till my crossmember is welded before I shift the car, then I can get it on a ramp.
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Ste L
Member
Registered: 3rd Jul 06
Location: Manchester Drives: 106 16v Rallye
User status: Offline
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i dont think they did, they haven't got a ramp...
would of just jacked the front of the car with the engine hoist, i would of though
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willay
Moderator
Organiser: South East, National Events
Premium Member
Registered: 10th Nov 02
Location: Roydon, Essex
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that is interesting 
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namkeaps
Member
Registered: 25th Jan 06
Location: manchester
User status: Offline
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underseal was put on while on axel stands afaik (i wasnt there at the time to help out) but it was put on as the pics show am sure of it
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Corsa_Carl
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Registered: 8th Oct 04
Location: Darlington
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wot a thread !!! cant wait till its finished
your car looks amazing to ! would luv it
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namkeaps
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Registered: 25th Jan 06
Location: manchester
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cage was in a pretty sorry state. bashed about so gave it a quick rub down with the help of ste and primered it up ready for a lick of paint. possibly tonight or tomorrow that will be done
its going to be black as to continute the black/white theme of the car
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richard_cooper
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Registered: 31st Jan 07
Location: Mansfield, Nottingamshire
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Good project
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John G
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Registered: 18th Jul 05
Location: Wirral, Merseyside
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is this the 4th corsa you were goin on about paul??
if so fuckin ace and best one youv had so far and uber fast progress,
how you gettin on after the women crashed into
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bieransri
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Registered: 13th Apr 06
Location: Kidsgrove, Staffordshire
User status: Offline
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wish i knew how to get my seat brackets off, mine are being a pain.
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Ste L
Member
Registered: 3rd Jul 06
Location: Manchester Drives: 106 16v Rallye
User status: Offline
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quote:
Originally posted by bieransri
wish i knew how to get my seat brackets off, mine are being a pain.
spot weld drill or grinder...
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bieransri
Member
Registered: 13th Apr 06
Location: Kidsgrove, Staffordshire
User status: Offline
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spot weld drill i have no idea how to use. tried it on one n it went straight through, tried the grinder got just about all the way through and its not budgeing
anyway looks bit like the corsa version of mine inside
[Edited on 30-08-2007 by bieransri]
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