Adams 1.8 LSi Saloon WIP

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Adamw5433
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Adams 1.8 LSi Saloon WIP

Post by Adamw5433 »

Hello all.

This is my WIP (Work In Progress) for my 1994, Vauxhall Cavalier 1.8 LSi Saloon.
Its a 1798cc, 8valve, Single point injection.
She's currently wearing Vauxhall Kings blue (22L).
Has covered 138k+ miles
As far as i have researched she was a fleet car from new until she was bought via auction.
I'm the 4th owner.

Ironically, she was destined for destruction to begin with.
As a donor vehicle for the red Cavalier hatch, which is now in Garys (Envoy CDX) ownership.
Having routed around undernieth the newly bought saloon, it would have been a shame to break her.
As it was found to be solid.

As with most Cavaliers her age, and older.
There was some corrosion to sort out, however nothing too serious.
So it was decided she was a keeper.


Picked up from Harrogate, ready for her return with me back to Darlington.
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On arriving back at Darlington, she was inspected and the following found:

Water pump seal, leaking.
Clutch pedal mega-heavy.
Alarming rust bubble on the roof.
Wind screen rubber, pulled out in corner. (repaired now)
Head light steamed up.

There have been other issues which have came to light since.
CV joint(s) require replacing.
Front wheel bearings shot.
Timing out.
Mis-firing.

New home for now.
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Rust bubble on roof, being investigated and tackled.
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So the Cavalier sat a week or so with no attenton.
Then came the mini-meet between myself and Gary as we cracked on with a few jobs on the Cavalier(s)

Investigating why clutch is mega heavy
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We never found the reason for the clutch benig mega-heavy.
However we've both decided it requires the box being dropped out.
While its out a new clutch kit may be going in.
Some work on the clutch release mechanism is going to be looked at too.

The aftermarket suspension from the red hatch has been swap to the blue cav.
There is now a custom back box from the hatch on the saloon and straight pipe, not too loud.
Rather nice actually.

However being from a hatch the back boxes tail doesn't clear the rear bumper.
Which will have to be dealt via a cut and weld mod to the backbox.
Or a new replacement back.

More progress to come as it happens

Adam
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btcctroy
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Re: Adams 1.8 LSi Saloon WIP

Post by btcctroy »

that rust on the roof looks bad sure it not worth cutting it out welding piece in. eventually it will start to bubble
....with a brew and my favourite biscuits.
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Envoy CDX
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Re: Adams 1.8 LSi Saloon WIP

Post by Envoy CDX »

Fairly well cleaned out and not very pitted.
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btcctroy
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Re: Adams 1.8 LSi Saloon WIP

Post by btcctroy »

the pics make it look like the rust has set in. personally I think it will come back through
....with a brew and my favourite biscuits.
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Envoy CDX
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Re: Adams 1.8 LSi Saloon WIP

Post by Envoy CDX »

btcctroy wrote:the pics make it look like the rust has set in. personally I think it will come back through
Hopefully not. Nothing is 100% though.
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Adamw5433
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Re: Adams 1.8 LSi Saloon WIP

Post by Adamw5433 »

btcctroy wrote:the pics make it look like the rust has set in. personally I think it will come back through
If it comes back, i know why and where it is.
Its had 3 treatments of rust killer on it.

I smoothed the first lot of filler and painted, as you see in the pics.
I got annoyed over the following days, with how pitted and rough the surface was.... mainly becuase i rushed the job.
So i strip the paint back to the filler.
Refillered so it was flat, however (as Gary will tell you) the new coat of filler refused to set.
Even after 9 days and lots of heat gun action.

So the entire lot was chipped out, right back to the metal.
Rubbed back to bare metal, re-rust killer'ed.
And filler built back up from there.
Now the problem is too much filler and a lump, in the middle of the prep work :wall
So need to sand the lump back flat.
Do one more pass with primer and rub back.... see if there is any high / low spots.
Sort them if any appear.
Then go for paint.

The filler / primer isn't high on my agenda just yet and the root problem has been dealt with and sealed.
We're just cracking on with various mechanicals, at the moment.

Adam
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Re: Adams 1.8 LSi Saloon WIP

Post by Adamw5433 »

By George!.... an update.

Things have been hit and miss at the moment.
However. Gary managed to sort out a nasty mis-fire (dying battery)

We bled brakes and found some rather nasty fluid coming out, so a system flush was decided on.
This is what came out:
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We or Gary.... someone, noticed the earth wire was a little suspect.
So it was changed for a larger diameter earth wire.
The old wire was then cut open by.... ME...
This is the condition of the wire i found
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We also sorted my Mondeo out with a (sort of) emergency repair, as the NSF wheel bearing was threating to collapse.
So a new hub and bearing was fitted. Old bearing is very very rough to turn.

More progress to come over the next few months :)

Adam
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Re: Adams 1.8 LSi Saloon WIP

Post by Lowrider Dave »

That brake fluid is foul! Nice to see progress is being made.
Lowrider Dave.

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Adamw5433
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Re: Adams 1.8 LSi Saloon WIP

Post by Adamw5433 »

lowrider dave wrote:That brake fluid is foul! Nice to see progress is being made.
Indeed from the colour and the bubbles that came out with it.
I can only assume at this point, that it has been boiled once or twice.
I doubt it has been changed at all in the last 5 years..... if at all.

Adam
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TurboDan
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Re: Adams 1.8 LSi Saloon WIP

Post by TurboDan »

Nice work there. Brake fluid looks nasty!
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Robsey
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Re: Adams 1.8 LSi Saloon WIP

Post by Robsey »

I guess you've never actually had this running on the road....
If the brake fluid is as old and possibly waterlogged as I suspect, then it's boiling point would have been quite low anyway.

Left in the car, it would have been next to useless, and would have rotted the brake lines rapidly... I'd make sure your line are clean of corrosion and cracks etc.


Regarding the earth strap - as the car is quite unknown, I would go through the entire power loom too.
All the way from the X5 connector, to the starter and onward to the alternator.

All good progress ....
Adamw5433
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Re: Adams 1.8 LSi Saloon WIP

Post by Adamw5433 »

Robsey wrote:I guess you've never actually had this running on the road....
If the brake fluid is as old and possibly waterlogged as I suspect, then it's boiling point would have been quite low anyway.

Left in the car, it would have been next to useless, and would have rotted the brake lines rapidly... I'd make sure your line are clean of corrosion and cracks etc.


Regarding the earth strap - as the car is quite unknown, I would go through the entire power loom too.
All the way from the X5 connector, to the starter and onward to the alternator.

All good progress ....

Pipe bender, and flaring kit on order.... awaiting delivery.
New pipes might be on the agenda, see what mock MOT comes back with (need to arrange that too)
If it requires new brake pipes i'll do them and the fuel pipes while i have the piping to hand.

As for electricals, thats an option i may explore.
However, it works for now. So will leave it alone.

Adam
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cavaliersri130
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Re: Adams 1.8 LSi Saloon WIP

Post by cavaliersri130 »

Good progress there m8 she's looking good.
I had that with my envoy when i changed fluid it looked liked it had never been changed in the 22 years.

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Envoy CDX
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Re: Adams 1.8 LSi Saloon WIP

Post by Envoy CDX »

It's getting there, maybe you'll fit your interior next week... :lol:
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Adamw5433
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Re: Adams 1.8 LSi Saloon WIP

Post by Adamw5433 »

The C20XE I bought as a potential engine swap for the Cavalier.
Is currently in the tear down / inspection phase.
Once again, I forgot to get pics as I just got on with it.

Must remember to take pics as I go and update the WIP :)
Pics tomorrow if I remember

Adam
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HAIRIBO
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Re: Adams 1.8 LSi Saloon WIP

Post by HAIRIBO »

Welcome back mate!
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Envoy CDX
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Re: Adams 1.8 LSi Saloon WIP

Post by Envoy CDX »

Looks like it was potentially a good buy. I should start on mine for a laugh - see how comes to bits and such.
Check the Rules!

Raw 8v Power! - Bad Cav, Naughty Cav... Cav want's to do 90!

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John Owens
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Re: Adams 1.8 LSi Saloon WIP

Post by John Owens »

Good to see your back into it mate :)
Adamw5433
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Re: Adams 1.8 LSi Saloon WIP

Post by Adamw5433 »

HAIRIBO wrote:Welcome back mate!
John Owens wrote:Good to see your back into it mate :)

HAHAHA

Cheers lads.


Ok so a little update on the XE.
Sorry for the poor quality pics (Camera phone)

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You'll have to believe me, when I say this was thick in dirt and oil.
Before it went in the parts washer.

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More updates to come as things progress.

Adam
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Re: Adams 1.8 LSi Saloon WIP

Post by gsi dave »

Getting there fella keep up the good work
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Adamw5433
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Re: Adams 1.8 LSi Saloon WIP

Post by Adamw5433 »

gsi dave wrote:Getting there fella keep up the good work
I am indeed.

The block and head are now at 'Ian Walley Racing' in Darlington.
Getting checked over making sure they are healthy.
In time I'll disclose why they went to Ian Walley Racing.
Rather than a run of the mill garage... as I have plans :)
And Ian is the man to help me, realise those plans.

So when I get the block and head back (HOPEFULLY) with a bill of good health.
I can continue on with the rebuild.

Adam
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Re: Adams 1.8 LSi Saloon WIP

Post by gsi dave »

No need to explain fella Ian is a very clever man
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Adamw5433
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Re: Adams 1.8 LSi Saloon WIP

Post by Adamw5433 »

My pc has died :(

So ive got pics of today's efforts, but cannot upload any just yet.
Adamw5433
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Re: Adams 1.8 LSi Saloon WIP

Post by Adamw5433 »

As above PC is dead, laptop is working fine... Now i have access to it.

So, today i painted the sump and intake manifold.
With what i a told is the color "Engineering blue".
Although someone pointed out its close to baby blue :s

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Preping the intake manifold for spraying... Also Halfords, Darlington are useless at times.
"What's masking tape?" i almost fell through the floor when the sales person said that to me


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Constructive comments :)

Adam
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Gaz
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Re: Adams 1.8 LSi Saloon WIP

Post by Gaz »

Watch your earth points now you've paintdd over them
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