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AL · Posted: Mon Mar 24, 2008 3:58 pm Post subject: My Mk3 Astra 'proper' Build

Guessed I better finally put a 'progress' thread up to show the 'proper' work that is being carried out on my faithful old Astra clap

I'm sure 99% of you know the car...

Apparently the 73bhp it made at Jamsport just isn't Vauxsport enough and therefore Chip doesn't love me anymore. So after endless bugging on here and a chance exchange of PM's with Mr Orange Peel, a deal was struck and I went off to Long Eaton to pull apart Neil's old Mk2 Astra CDi.

The trusty 'Van of Love' was borrowed for the trip - so nice to drive compared to my Astra LOL

Comfortable, power steering AND working heaters. Amazing.

Did a lot of this, with other associated fucking around...

Then took the easy option and dragged the engine from under the car...

Theres a few bits that I still need to get: throttle cable, in tank pump, engine mounts and a few other little bits and bobs. But here it is, sat in my garage:

Along with the suspension that I bought - standard shocks with -60mm springs. Not ideal so am going to get my bilsteins with Koni springs swopped over I think.

Originally I was hoping to do the work over the Easter Bank Holiday weekend, however the dude I got the suspension from let me down on those twisted

So in the meantime i've done a couple of little bits, namely stripping the old mounts off the engine, giving it a bit of a clean and just doing a few visual checks. The cambelt has only done a couple of K, tensioners and water pump the same. Needs a sump gasket, rocker gasket and a set of plugs but otherwise looks to be in good condition.
There is a bit of oil/residue in exhaust port #3, which I assume is down to stem seals. I'll see if/how much it smokes when its running - if its too much then i'll whip the head off and sort it out.
Aim of the game is to do this as cheaply as possible LOL

I have an oil pressure gauge on the way, a short shift linkage coming and some Roose water hoses if Chris Astley get their arses in gear Nod

Spent half an hour cleaning the manifold up this morning - its in VERY good condition except for the end flange that meets the system is a bit work - I may chop this off and weld a new flange on when I mate it up to my current system (Piper cat back).
Gave it a rub down with some 400 grit then applied Hammerite 'high heat' paint - in matt black naturally. Heat gun used between coats and it has come up stunning - will look great I think smile

Can sort of see how it looked before in this pic:

And painted...

Had a nice long list of other bits to do this weekend but just about managed to swop the wheels front to rear (MOT Advisory, front inner edges on 2mm - rears are nearly new) then got bored with snow showers so have given up basically. I have however had chance to think about other bits, I have placed an enquiry with Custom Cages for one of their Core Kits - just a 6 point weld in cage with rear diagonal and no door bars.
If I get the cage, i'll be losing the dash and heater matrix, then adopting something like the pic below, minus any unneccessary wiring:

Have decided that once it is built, it will pretty much become a weekend/occasional evening toy. Would much rather it stopped in the garage and I get the train than have the temptation to thrash it every day Nod

Future plans include:
Eibach ARB's
Better Suspension (including poly bushes)
New sunroof of some form...
Ashley manifold & system (quoted £450-£500 for the lot Cool

)
Nitrous! Purely for the strip though.
Perspex side windows.
Weight saving - including me going back to the gym Shock

Decent fixed back buckets.

Wish me luck folks! Thumbs Up

Turbocraig · Posted: Mon Mar 24, 2008 4:15 pm Post subject:

Keep at it AL.

No dash is a bit extreme!!

AL · Posted: Mon Mar 24, 2008 4:48 pm Post subject:

philip2 · Posted: Mon Mar 24, 2008 6:12 pm Post subject:

you dont need a dash lol Thumbs Up

AL · Posted: Tue Mar 25, 2008 9:28 pm Post subject:

Damn right dude! Looknig forward to stripping the wiring out and scaling it all down :DMight have to wait until after combe though...
Main bonus is gonna be losing the dash where I keep bashing my knee during spirited driving LOL

Sliiiight update tonight, done a bit of cleaning up and painting stuff tonight. My theory is: stuff that is clean and freshly painted will meet parental approval far more than the rusty shit that I stupidly boguht off a pleb on Mig!
Very disappointed with the condition of the struts considering how they had been described, let alone the raditoar (apparently 'mint condition' means: 'smashed a bird to pieces, feathers included for free') - bearings seem ok, springs look fairly new (although I think one is upside down PMSL

) shocks are the originals... Quick scrub with some degreaser, attacked with the wire brush and a dollop of Hammerite. matt black on the disc backing platesm, the rest in gloss black.
Much better!

Started painting my shafts too, mainly because i'm a tart:

The refurbed inlet I bought on eBay - might get a new gasket and match it to that ready for some head work later in the year smile

Got my oil pressure gauge through too, just need to figure out the wiring on it (came with a sender but need to figure out where it plumbs in...)

But never never again am I buying anything from Benn on Mig...bastard LOL

All shits and giggles eh? beer

Haynzee · Posted: Tue Mar 25, 2008 10:02 pm Post subject:

refurbed inlet PMSL

what did they refurbish exactly? spray it with silver paint without removing the water takeoff or studs? bargain! sure it will add loads of bhp Confused

Ditch the disc shields if your into saving unsprung weight

whats this parental approval nonsense? havent you told them your fitting an engine that makes the car 20x more dangerous in the hands of a street racing loon?

LOL

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Trouble · vauxsport.com Joined: 19 Jan 2008 Posts: 26

fennyLET · Posted: Wed Mar 26, 2008 9:47 am Post subject:

Ive forgot to say that at the moment i havnt got any spear mounts lying around. Il try to get Ricky (Who works in the breackers yard) to get them of a 2.0 sport we have.

AL · Posted: Wed Mar 26, 2008 2:12 pm Post subject:

fennyLET · Posted: Wed Mar 26, 2008 2:17 pm Post subject:

Il have a go mate

AL · Posted: Wed Mar 26, 2008 2:22 pm Post subject:

AL · Posted: Thu Mar 27, 2008 2:37 pm Post subject:

Haynzee · Posted: Fri Mar 28, 2008 6:00 pm Post subject:

Said i'll rib you till its fitted PMSL

if your still stuck for mounts the cav and calibra ones are the same so get down t'scrappy - seems to be loads about whereas not many bigblock mk3 astras
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AL · Posted: Fri Mar 28, 2008 10:15 pm Post subject:

Think I know of a Calibra XE local, will have a trip out tomorrow.

Are the rear mounts the same too?

beer

Chris Astra · Posted: Fri Mar 28, 2008 11:12 pm Post subject:

Good work Al, be a good little beast when she's done.

Customs Cages? Gen please.

Haynzee · Posted: Fri Mar 28, 2008 11:44 pm Post subject:

im pretty sure i used my standard 1.4 rear mount when i did my 2.0 conversion, mind you it was 6 or 7 years ago
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AL · Posted: Sat Mar 29, 2008 9:33 pm Post subject:

Kev_mk3 · Posted: Sun Mar 30, 2008 1:42 pm Post subject:

good work al - bout time it had the engine ;) as for ARB's didnt know Eibach did them?

have you got GSI ones fitted at the moment? also i would keep the dash mate seriously

LETSTICK · Posted: Sun Mar 30, 2008 5:24 pm Post subject:

Chris Astra · Posted: Sun Mar 30, 2008 6:15 pm Post subject: