Retro Power Posted January 9, 2010 Share Posted January 9, 2010 (edited) Thought it was about time I got my ar$e in gear and shared this little project with you all! It's nearly finished now, so the final pics should be added in the next couple of weeks 8-) Starting point was not too great! The car was dragged from a field, where all manner of wildlife had decided to take up residence in it! Rat eaten interior, birds nest behind the headlight, and so many horrible bugs behind the trim we barely dared touch it!! First job was to strip the car down and inspect the rot. We had already had a bit of a look over the car and knew it wasn't as bad as it looked. Only significant rot on sills and rear arches. Sills are fairly straightforward as you can still get repair sections... Didn't take any pics of the finished sills for some bizarre reason? Anyway, on to the arches which was a tad harder as 4 door repair panels are no longer available! The nearside was not too bad, so just the lip section from a 2 door repair was butt welded in and lead filled. On the offside, the rot extended in to the door shut area, so this section was fabricated from scratch in steel, and lead filled. Very Nat (my brother, who does all the fabrication work) did an awesome job here, there was virtually no filler needed to get the final shape, it was almost bang-on in the bare metal! Edited January 9, 2010 by Retro Power Quote Link to comment Share on other sites More sharing options...
mantadoc Posted January 9, 2010 Share Posted January 9, 2010 Considering that's been in a field (ok depends how long) looks like you've has surprisingly little to do. PS if you deal with Chevettes a lot you can stil get a fair bit of stuff for them. A pillars, Battery trays, wing rail repais.......... basically all the Klokkerholm Kadett stuff that fits (other parts sources are available). Rear axle mount to floor parts are a bit intermittant to get but rust terrible between the skins. Quote Link to comment Share on other sites More sharing options...
Retro Power Posted January 9, 2010 Author Share Posted January 9, 2010 Considering that's been in a field (ok depends how long) looks like you've has surprisingly little to do. PS if you deal with Chevettes a lot you can stil get a fair bit of stuff for them. A pillars, Battery trays, wing rail repais.......... basically all the Klokkerholm Kadett stuff that fits (other parts sources are available). Rear axle mount to floor parts are a bit intermittant to get but rust terrible between the skins. Yeah, as I said, not as bad as it looks on the surface, which is a pleasant and very rare suprise! To be fair, before being parked up it had only done 25,000 miles! The Battery is moving to the boot to give us a bit more space in the engine bay, so this area was refabricated (with a slope to allow water to run off) and then the engine bay sandblasted and coated with zinc primer. Meanwhile, we relieved a Calibra of it's engine and gave it a quite trial fit to check for clearances etc........ ......then cleaned it up (inlet manifold, engine mounts, alternator mounts, alternator casing and various other bits have been glass bead blasted). Also receiving a good seeing too from the blaster (this time with steel grit) are the axle (which is a Manta A item, with panhard rod mount swapped to the other side, and the chevette crossmember grafted on) and all the suspension components. They were then all painted in 2K gloss black. The axle also had the spring pans replaced (with good ones from a Manta B axle) as the originals were rotten through. at this time, the shell was in the spray booth to start it's transformation to 'Jade Green'.... Usually not a colour I would consider good, but I think it works here! Quote Link to comment Share on other sites More sharing options...
Fasterthanyou Posted January 9, 2010 Share Posted January 9, 2010 Haveing seen the end in the flesh it was good to see the beggining! missed that part. Cool colour, def suits it. Quote Link to comment Share on other sites More sharing options...
Retro Power Posted January 9, 2010 Author Share Posted January 9, 2010 OK, on to assembly. Obviously we aren't going to stick with stock suspension/brakes. OE spec Bilsteins up front and Boges rear to give it a bit more precision, without being too hard (it's going to be a daily driver!) in combination with slightly lowered and uprated Kadett C springs from Germany. Lost track of how many times I've seen recommended astra discs redrilled to fit the back of the hubs, and astra calipers as the std chevette upgrade, but believe me, it doesn't work, as the caliper hits the wishbone with the suspension on droop. We've machined the hubs to allow the astra discs to fit on the outside, with the caliper mounting faces milled down slightly, and mounted to the outside of the mounting lugs. Sorted! Engine is (not suprisingly) tight with the standard injection system. Pug 106 master cylinder has been used, on a fabricated mount to get it tight in to the bulkhead in order to clear the inlet manifold. Reservoir mounted remotely on the old throttle linkage bracket. Exhaust manifold is an Ashley RWD XE one, modified to fit, and with the powdercoat burt off and replaced with VHT paint (when will ashley stop putting a non-heat resitant finish on their manifolds!!!!) Gearbox is Manta B 1800 with a custom x-member. Prop is Manta B automatic which is the correct length No room for std SFI box or indeed a 'powercap', so we've fabricated a stainless induction pipe. Rad is a VW polo jobbie, with leccy fan infront. And yes, as you can see we have managed to keep the standard heater arrangment (obviously this is a late, dizzyless type XE). Quote Link to comment Share on other sites More sharing options...
mantadoc Posted January 9, 2010 Share Posted January 9, 2010 I'd say MK4 Escort battery tray? I used one on my wife's Kadett before spotting the unboltable Vectra B tray which looks so like the Kadett C tray it's untrue. Also a small gusset on the bottom of the lower wishbones pays off in two ways, keeps the edge from folding up and twisting if you catch something, but also gives two very convenient jacking points. Gussetting the "n" section front crossmember is worth while too and makes it nearer to the HS / HSR spec that curved the skid up to protect the rack. Very nice car undeed. Quote Link to comment Share on other sites More sharing options...
manta400john Posted January 9, 2010 Share Posted January 9, 2010 Definately a "sleeper" colour-not sure i like it but looks like a standard colour? What about wheels......will 13's fit? John. PS Looks a nice wee car Quote Link to comment Share on other sites More sharing options...
vauxsenb Posted January 9, 2010 Share Posted January 9, 2010 Seriously, it has to wear Minilites with polished rims Quote Link to comment Share on other sites More sharing options...
bendy Posted January 10, 2010 Share Posted January 10, 2010 Very nice, i do enjoy a sleeper. I always thought a tasty 3 door saloon chevette would be cool too. Interesting way to go about the brakes, how close will that take the calipers to the back of the wheels? Dont see why this couldnt work on a manta so you could use OE discs, im asuming you just had to machine down the outer edge of the hub face so it would fit inside the bell of the disc? Great work Quote Link to comment Share on other sites More sharing options...
Retro Power Posted January 11, 2010 Author Share Posted January 11, 2010 Very nice, i do enjoy a sleeper. I always thought a tasty 3 door saloon chevette would be cool too. Interesting way to go about the brakes, how close will that take the calipers to the back of the wheels? Dont see why this couldnt work on a manta so you could use OE discs, im asuming you just had to machine down the outer edge of the hub face so it would fit inside the bell of the disc? Great work :thumbup The wheels clear ok, infact to get it rolling we had std 14" manta Ronals on, which were ok. TBH I usually just go for Carlton vented discs and 16v calipers on a manta which are a straight on fit... The pads overhang the disc slightly, but it's never caused me any problems. The issue with the shuvvit is that with the 16v calipers bolted on in the usual way, they hit the wishbones when you steer with the suspension on droop.... quite badly in fact, reduces your steering lock by about 1/4! Seriously, it has to wear Minilites with polished rims Funnily enough we were going to fit 15" Rota RB's .... Have a look at these pics, they look the business! However, the Chevette is quite a tough car to get the fitment right on. Too inset and the front tyres hit the shocks on droop, and too far out and the rears hit the arches. In fact with 6" wheels you have about 10mm variation in offset possible (-35 to -45). Manta Ronals are very close to the lip at the back. We eventually settled on 6x15 VW 'winter' steels (ET-38), which I recon work really well. at £140 a set brand new you can't argue with the price either:thumbup Ooh, nearly forgot to mention the fuel tank arrangement. Return line union soldered into the level sender cap, and a Golf GTI fuel pump (with integral swirl pot) used. Moving to the inside, it's all being kept very 'classic' looking. Dark green leather seats come from a Rover 400, and door cards are being retrimmed to match. Alpine speakers fitted behind rear armrest and in front kick panels. Thatcham cat 1 alarm also fitted at this point plus wiring for guages..... Original dash modified so that a Manta B rev counter sits where the fuel and temp guages once did. Manta B fuel, temp, oil press and volt guages are being fitted to dash where the central speaker used to go..... It's all being made to look like O.E. Snaps of the aux guages will be added later as I've not taken any yet. The whole car is being 'aged' with the pre facelift parts (headlamps, c-pillar vents, chrome trim etc) which look a bit smarter imo.... You'll have to wait to see the finals pics ;D Quote Link to comment Share on other sites More sharing options...
keith1200 Posted January 11, 2010 Share Posted January 11, 2010 Very nice Quote Link to comment Share on other sites More sharing options...
Irmscher Man Posted January 11, 2010 Share Posted January 11, 2010 Awesome....some really ncie ideas there. Always had a soft spot for Chevettes. Quote Link to comment Share on other sites More sharing options...
Shuviteer Posted January 11, 2010 Share Posted January 11, 2010 That is looking nice. Best about saloons is you don't have to mess about with the rear suspension as it is the same as the HS/HSR set up.Thing that Jade green colour is spot on, and especially with those wheels. Don't know if you hasve thought about putting in a 'works' style dash ?I once had one, it had a full 'binacle' instead of the small drivers side one,so went all the way infront of the passenger side.Got it from Ian Jemisson Engineering in York (well just ouytside ).This was a few years ago, and he had a few Chevette bits then, after all he did have Tony Ponds works car sat in his back shed waiting to be repaired/reshelled !! Worth a call if interested, might still have a copy left. Quote Link to comment Share on other sites More sharing options...
Retro Power Posted January 11, 2010 Author Share Posted January 11, 2010 (edited) That is looking nice. Best about saloons is you don't have to mess about with the rear suspension as it is the same as the HS/HSR set up.Thing that Jade green colour is spot on, and especially with those wheels. Don't know if you hasve thought about putting in a 'works' style dash ?I once had one, it had a full 'binacle' instead of the small drivers side one,so went all the way infront of the passenger side.Got it from Ian Jemisson Engineering in York (well just ouytside ).This was a few years ago, and he had a few Chevette bits then, after all he did have Tony Ponds works car sat in his back shed waiting to be repaired/reshelled !! Worth a call if interested, might still have a copy left. Actually, those Rota wheels in the pic are not what we have used (they don't fit properly), just shoved them on another Chevette we had lying around to try them! We have used VW steels in the end... Here is a sneaky snap of the outside, but I'll post loads of pics when we get the door cards back from the trimmers. As for the dash, I recon the one we have done looks the dogs bits! Early style (non side vent) black dash with guages fitted where central speaker once lived.... All made to look OE.... Will make sense when you see the pics Edited January 11, 2010 by Retro Power Quote Link to comment Share on other sites More sharing options...
deanosabby Posted January 11, 2010 Share Posted January 11, 2010 Looking good there. I had an 83 hatchback as my first car back in 93 that had turreted suspension on it, lowering springs, peco exhaust and so on. Loved the handling on these and always thought they were way better than all my mates fwd fiesta's. Quote Link to comment Share on other sites More sharing options...
mantadoc Posted January 11, 2010 Share Posted January 11, 2010 This looks like one of those occasions where having a set of the Kadett GTE / SR clocks that I think they also used in Chevette HS / HSR lying around (like me ) would be handy. Quote Link to comment Share on other sites More sharing options...
Volksdevil Posted January 12, 2010 Share Posted January 12, 2010 Great thread, love reading topics like this. Some good ol' Vw bits too eh? Those steel wheels are for Corrado and Passat G60's for anyone else interested. (Recently become rediculously popular in the Vw scene) Anyway...Great looking motor and it looks like you do a smart job of things. Neil. Quote Link to comment Share on other sites More sharing options...
IanMc Posted January 12, 2010 Share Posted January 12, 2010 Nice job, subtle but going to be very 'effective' when on the road Liking the boot badge........ Quote Link to comment Share on other sites More sharing options...
keith1200 Posted January 12, 2010 Share Posted January 12, 2010 (edited) Them steel wheels look 'spot on' hmm cheaper and possible an better option, than buying Halford style alloys. The paint is spot on! modern but yet right period colour Near forgot to ask! how did the rover interior fit? something you would recommend to other chevette owners? Edited January 12, 2010 by keith1200 Quote Link to comment Share on other sites More sharing options...
Retro Power Posted January 12, 2010 Author Share Posted January 12, 2010 Them steel wheels look 'spot on' hmm cheaper and possible an better option, than buying Halford style alloys. The paint is spot on! modern but yet right period colour Near forgot to ask! how did the rover interior fit? something you would recommend to other chevette owners? Cheers. The whole idea from the start with this car was for it to be subtle, but effective... Almost as if it was made this way from Vauxhall! The Rover interior is a pretty good fit, only downside is (as you can see in the pics) virtually no rear seat leg room, making it more of a 2+2! The fronts a tight, needed to modify the reinforcing section that runs over the tunnel behind the handbrake. Welded small brackets directly to the tunnel/sills and bolted the seats in using the original subframes. Removed the integral seatbelt sockets (mounted to the seat in a Rover) and the Chevette sockets sit perfectly in the 'cutout' on the seat base trim. Rear is perfect width. Will look smart with the doorcards, which are being trimmed to match exactly. Quote Link to comment Share on other sites More sharing options...
cact1972 Posted January 12, 2010 Share Posted January 12, 2010 I have seen this car in the flesh just before the wheels the were fitted, Its a true credit to the guys and the attention to detail is second to none! Quote Link to comment Share on other sites More sharing options...
Retro Power Posted January 13, 2010 Author Share Posted January 13, 2010 (edited) I have seen this car in the flesh just before the wheels the were fitted, Its a true credit to the guys and the attention to detail is second to none! Cheers Curt Looking forward to working on the Ascona Edited January 13, 2010 by Retro Power Quote Link to comment Share on other sites More sharing options...
Retro Power Posted January 27, 2010 Author Share Posted January 27, 2010 (edited) Sun has been out today, so took a couple of snaps outside.... It's covered in dust, but still looks pretty cool 8) Still waiting for the door cards back from the trimmers though Here is the dash, you can see the aux guages I was on about. Manta guages, mounted in the old speaker position. Covering panel is ally, with bevelled cutouts machined out for the guages, then painted satin black, and the lettering engraved through to the ally. rev counter is Manta, mounted in original instrument pod. Nice period Wheel fitted, and retro looking Pioneer CD tuner fronts the new audio system. Edited January 27, 2010 by Retro Power Quote Link to comment Share on other sites More sharing options...
SENNA1 Posted January 27, 2010 Share Posted January 27, 2010 Nice wheels Quote Link to comment Share on other sites More sharing options...
bendy Posted January 27, 2010 Share Posted January 27, 2010 Looks the dogs nuts, gauges are tidy too Quote Link to comment Share on other sites More sharing options...
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