1992 Cavalier Turbo 4x4

[lem0nmonkey]

Heres my cavalier turbo

How it looked about a year ago

[lem0nmonkey]

Then the turbo died and did some work under the bonnet

some new parts





and fitting it all in




also relocated the battery into the boot

[lem0nmonkey]

And right now the grey one is in storage and i have purchased another shell, generally much tidier and straighter other then needing a bit of fixing after a rear end shunt.

when the previos owner had it


its now looking a little sadder, although overtime it will be restored and returned to its former glory although, slightly, upspecced!!!



taking the engine out for its new owner,



and the damage thats caused it to be in its current predicament






its barely moved the rear panel at all, maybe about an inch, and its twisted where the light is slighly at the bottom, but only a small amount so hopefully it'll all knock back out and then i just need to get a new rear bumper support bar and jobs a goodun!!

[Gaz]

weld a bolt onto the back panel and slide hammer it out, will pull it 99% out if you get the middle of the impact

Love the smoke grey turbo.

[Colorado]

Worth saving. let us know how you get on with your rebuild. The grey one looks great.

[LETSTICK]

Remember the grey cav from another forum , new one looks clean apart from the rear end damage

will be watching the out come , keep up the good work

[specks]

so,hope you ain`t killing the grey one to rebuild toy,marks then sams black one

[FoxyCav]

thought i recognised that grey Cav. seen it a while ago on the Vxon forums. Not a fan of modded up Turbos (standard is best on these imo) but i did like the look of that.

[Envoy CDX]

Looking good, as Gaz said, sliding hammer is the way forward

[lem0nmonkey]

the engine and running gear will be going into the black shell, as overall its in better condition than the grey one, although once the grey ones stripped, i will be doing a bareshell overhaul of it, learning to weld and this will be a project for me to get into once the black one is completed, plus ive pretty much got enough spares to rebuild 2 turbos anyhow, think i'll put the grey one back to a standered mint example externally with maybe a few upgrades under the bonnet,

[Envoy CDX]

think i'll put the grey one back to a standered mint example externally with maybe a few upgrades under the bonnet,

Oh good, the stripped out look, was to be honest making me a little yucki

[specks]

thank god the grey one will still be about,nearly gave me a heart attack when i read this thread

[lem0nmonkey]

nah, tried the stripped out look and wasnt convinced, to noisy, you can shed wieght in a car without sacraficeing a little comfot, so both cars will have some pretty plush interiors, what with my trimming skills,

yeah couldnt get rid of the frey shell, currently the oldest cav turbo on the register, would be a shame to scrap it,

karl

[Colorado]

What was the reg date? mine was Feb 93 mine must be one of the older ones too.

[lem0nmonkey]

grey chell is nov 92, currently the earliest on the ctor register other than an ireland model which doent have a date, black one is 1st aug 93

[lem0nmonkey]

update, i have since knocked the boot back into shape and it now shuts and locks although still slightly out on the right side so a little more shaping is needed
with a rubber hammer and a block of wood,!!

the engine running gear from my grey one will work its way into this shell as overall its in better nick than the grey shell, i will then restor the grey shell

picked up my new block!!





iasa forged low comp pistons, steel rods, oil spray,

giving it a couple of coats of satin black hammerite, then i'll start building it up to mock up a new exhaust etc!

and transfer all the parts from the original engine! all in it should knock on the door of 400bhp!!

[branny361]

nice .... you got the engine and stand in the house ?

[lem0nmonkey]

nice .... you got the engine and stand in the house ?

yeah, its warmer to work on, has more space and security than my garage, seeing as theres a car filling my garage,

and the engine wont be fully assembled in the house, in there to have the manifold adjusted and the first part of the downpipe mocked up and screamer pipe etc, it'll then be stripped back down and reassembled whilst going in the car.

[lem0nmonkey]

made some more progress today, had been waiting on the let head flange, found a nicely made one at the right price, as some of the ones available are a little overpriced,


anyhow, bolted them both to the head, gonna need to use longer studs on the lower holes due to the thickness of both flanges, somewhere around 24mm once welded together,


areas that needed trimming for clearence




also needed to trim the top off the evo flange as it gets on the way of some of the bolts, 12mm stainless is think old stuff to cut with a grinder, need to invest in a plasma cutter as some point!!


once was happy that it was about right i tacked the 2 flanges together ready to be refitted with the rest of the parts on the engine to check clearences etc.

cutting v edges into the flanges to aid the welding of such think peices,




tacked together


need to drill a couple of holes, then its mock assebly time and make sure everything clears ok, then weld it together properly!!

[lem0nmonkey]

ok, got all the other bits for the front of the engine together and bolted on today, need to check clearences etc, which is much easier whilst off the car!!

only real issue is the dipstick and breather tub, but a bit of grinding on the comp housing should sort thats nicely, also gonna design a brace for the turbo to the block to support the weight and minimise the cracking to the manifold.

pics

[Gaz]

will there be any issue with the turbo being that close to the block? Temperature wise?

[TurboDan]

I doubt it, should be fine. The standard turbo is pretty dam close to really.

[lem0nmonkey]

compresser housing gets no where near as hot as the exhaust side, so shouldnt cause any issues, plus like dan said that standered turbo is also quite close but the other way round. only issue might be with teh oil return as its quite close to the elbow, but some high temp pipe with heat protection round and plus making as much of it out of steel pipe should help

[lem0nmonkey]

not a huge update, waiting on ss welding wire and some gas for the welder till i can do some more work on the turbo,

however i did start on tidying up other parts of the engine, the blocks painted in satin black smooth hamerite, so most of the rest of the engine will be aswell

cleaning and painting the offside mount

[lem0nmonkey]

not much progress on toy, but i have started stripping more off my grey cav, and got it up on its dolly