Mk3 Cavalier Owners Club | Vauxhall Cavalier Dot Com

Good work Tony, I like the idea of power coating. I always planned to do stuff this way myself but things always seem to be rushed around here!

Great progress, love powdercoating

Whats your plan for the icv?I see you have cut the std boss out.
I blanked mine off, made an ally block and welded it on the rear of the plenum above cyl5.
You will need a longer servo pipe,I got one off an old corsa,1.2 iirc,perfect size and bends.

iancav6 wrote:Whats your plan for the icv?I see you have cut the std boss out.
I blanked mine off, made an ally block and welded it on the rear of the plenum above cyl5.
You will need a longer servo pipe,I got one off an old corsa,1.2 iirc,perfect size and bends.

I've had a spigot welded on over the egr holes, and will attach the icv to this with some tube. Already got the servo pi pe off a corsa ready to drop on.

This is my set up.
What are you going to do to get the twin TB inlets into one?
As you can see I had a Y piece made,joined to the TB with Samco hose.Its all a bit tight for space where the two hoses spigot onto the TB,I had to carefully trim the hoses and offset the jubilee clips to make it fit.
As yours is the long nose plenum,how are you for space to the inner wing?I have one of these to try aswell,be interested to see how you do it?

It's looking good Tony

Right, finally got round to doing some on this. After putting it off for ages, I got cracking cleaning the underside up. It wasn't too bad as I'd had the car steam cleaned before taking it off the road, but under the arches were still pretty bad. Also removed all the exhaust heat sheilds as I wanted to make sure there weren't any horrors lurking underneath. They only rattle anyway! Didn't get any before pics, but here's the underside after cleaning:












As you can see, it's very solid! There was only one patch of rust that was any more than surface, just behind the back wheel on the boot floor:



Then I chucked the best part of a litre of seam sealer at it. I was amazed the number of panel joins that had absolutely no protection whatsoever:

Good job!

So yesterday I cracked on with the horrible job of undersealing the car with underbody shutz. I spent more time masking off beforehand and tidying up afterwards than I actually did putting the damn stuff on (including a trip to Machine Mart as I ran short of shutz before I'd finished!), but it's done now and I'm happy with the results:

All good, I'd look at those rear arches before it really sets in though.

Been doing some odd jobs on the Cav, in amongst some other jobs. Fitted the towbar:



Started painting up some wheels:



Made a start on painting the engine bay:



Finished painting the wheels:



Finally fixed my vice to the workbench. Don't think it's going anywhere in a hurry!:



As the Omega inlet won't let me use the standard airbox, I removed the naffy brackets from the inside wing, re seam-sealered, and generally seam sealered any other bits I could see around the engine bay:

Great work!

Made a bit more progress on this over the weekend. Finally (after about a year!) got my MIG welder put back together (it now has a new CO2 regulator and a Euro torch - much better!), so I was able to weld up my removable battery tray, made from a Vecra B tray and part of the old bracket, as on its last incarnation, the battery tray was always in they way, as were the PAS pipes. New tray:



Then I finished cleaning up the engine bay and gave it a coat of stonechip:





Then it was time to crack out the satin black on the battery tray:



and the engine bay. I think I got more paint on me than the car, but it all worked out well in the end:









Looking a lot better now and more hungry for an engine to fill it!

That looks impressive and I have always wanted a bolt in battery tray in the cav!
Looking smart that engine bay!

Envoy CDX wrote:That looks impressive and I have always wanted a bolt in battery tray in the cav!
Looking smart that engine bay!

Cheers Gary. The bolt in battery tray wasn't too hard to do. In hindsight I could have got away with keeping the original Cav tray and bracket, and just using some of the holes from drilling out spot-welds to put bolts through to the captive nuts (the captive nut tool is brilliant).

Nice work, I wish I had a removable battery tray on my V6, damn thing gets in the way!

lowrider dave wrote:Nice work, I wish I had a removable battery tray on my V6, damn thing gets in the way!

Yeah, it's taken me a while to get around to it, but I'm glad I did as it was always in the way on the last V6. Adjusting up the clutch was a half hour job and always resulted in skinned knuckles!

Part of me wants to go out and crack on, the other part thinks it's too bloody cold!

love all the work going into this cav, top job mate, I can appreiciate all the work that went in the floor pan etc, as I spent weeks in a cold damp garage doing the same to my cav turbo, its hard work at the time but well worth doing, keep up the excellent work mate Ads

Ads wrote:love all the work going into this cav, top job mate, I can appreiciate all the work that went in the floor pan etc, as I spent weeks in a cold damp garage doing the same to my cav turbo, its hard work at the time but well worth doing, keep up the excellent work mate Ads

Cheers ads! I've got a day off work tomorrow so that will probably be spent in a cold garage under the car (why didn't I take the time off in the summer?! ). Hopefully it will be above freezing, lol!

Looks very solid, not many left in that condtion.
Great work btw

Some good work going on there!

himselfunknown wrote:

Envoy CDX wrote:That looks impressive and I have always wanted a bolt in battery tray in the cav!
Looking smart that engine bay!

Cheers Gary. The bolt in battery tray wasn't too hard to do. In hindsight I could have got away with keeping the original Cav tray and bracket, and just using some of the holes from drilling out spot-welds to put bolts through to the captive nuts (the captive nut tool is brilliant).

Yeah, looking at the nutsert tool myself - used them in college a while back and very handy bits of kit.

Been cracking on with some more bits and pieces. Now have the LPG fuel line fitted, the LPG tank filler line, and the the filler attached to the towbar bracket. Also upgraded the towbar electrics bracket as the old one was bent and looked awful:



Painted a few more bits and pieces, includin the ABS modulator:







and also got the rear arches primered up. Already looking a lot better:

Massive improvement Tony.

That looks mint good work