1994 Cavalier LSi C20NE (was C18NZ) Work-horse

[ilovedmymantas]

It would be far easier, tidier and cost effective to get an after-market single din radio with a flip out display.

No dash modifications required.

I agree, with reservations, because this is what I did.
Pics here viewtopic.php?f=21&t=14042
It's great to have a multimedia head unit that does everything but there are drawbacks.
Mine is slightly longer/deeper ? than a standard radio, so it stands around 5mm proud of the radio aperture (disguised with black insulation tape on the front of the cage as a temporary measure ).
Map updates may be a problem unless you're going for one that's worth more than your car ( mine uses igo, little quirky but ok for now)
The two main possible problems imo are :
you can't see the clock/temp/trip computer or access the heater controls without dropping the screen.
The other problem if you're using the sat-nav is glare (especially if your passenger is wearing white clothes ! ).
On reflection( see what I did there ? ) it may be better to fit a unit like this in the centre vents. (this is where I fitted the gps antenna, after much blood-letting ! )
Don't know if it is better but theoretically should be.
On the plus side , when driving and you're not using sat-nav,(screen-up) it's great

[Robsey]

There are some very simple non-flip-out VDO / Philips single din navigation radios, but navigation is by arrows and symbols (no maps) on a very small screen.

Again an alternative is to remove an air vent or modify the central vents and fit a smallish sat nav unit such as a motorcycle satnav or a small compact tom tom unit.
My Tom Tom One is very small by modern standards and would probably fit quite well. It is possible to have a usb lead permanently attached to allow updates via a laptop or something.

[Robsey]

The first of the chassis legs being offered up to check fit and of course - alignment.

One chassis leg is being done, before the other is cut out, to ensure the most accurate repair.





A slow but very important stage in the restoration...

[planetc]

Bloody hell Rob, I've just had a catch up! You've got some hours in this between you and Troy haven't you, looks like you are getting somewhere though.

[Robsey]

It is all Troy's effort.
Apart from taking photos or posting up Troy's pictures, I haven't done a thing on the car since early July.

I am just ponsing about with making up a fresh dash loom for all the CANbus system with a planned integration to an accessory live and ignition live feed.

This will need me to change the ignition switch and connector to the one in TurboDan's or Gaz's WIP.
My current switch does not have an accessory live pin.

[Colorado]

Looking very good. Where did you get the chassis leg repair panels?

[Robsey]

They are Klokkerholm parts from Holland. (See page 42 of this WIP)
Troy gave me a link to Carz2, who were able to buy them in for me.

About £120 per side (free delivery for order over £100) but they come fully assembled with all hangers, spring seats and all three skins pre-assembled and in a good coating of black protective paint.
This hopefully saved Troy plenty of hours of making up three different layers of repair panels.

(Minor UPDATE - approx 6 months after posting this, the Carz2 price for these parts has now been reduced to virtually half price - bad news for me, but good for anyone reading this in mid 2016...)

First impressions from Troy was that they looked reasonably well put together, and the left leg was said to be "not far out" when tried for fit the other evening.
The right side will be worked on after the left side is complete.

My only niggle was that Klokkerholm forgot to ship out the left chassis leg for a whole month. Not a big issue as Troy and I planned well in advance. (Read that as Troy prompted me early on - ha ha).

For their part, Carz2 kept me informed of the progress of my parts, and were willing to provide a refund without any quibble if I was able to source my parts elsewhere in the interim.

[Robsey]

The underside is cleaned and painted ready for the chassis leg to be welded in (any day now )





I am threatening to see Troy's progress on Thursday evening, although I usually try to keep out from under his feet.

Very impressive work, when you bear in mind that this is NOT up in the air on ramps - he is doing this on his back on the floor.
Makes my neck and back ache thinking of all those times that I lay under the car fitting stuff like brake cables or fuel lines - eek!!

[Colorado]

Thanks.I am impressed with the quality of the parts and how it is being repaired. Your going to have a cracking car by the end of this

[Robsey]

I agree -
A massive amount of care, attention to detail and thought have been put into the old girl.
It should be one hell of a stunning solid car when completed.

Part of me feels quite guilty, because the car was simply run into the ground over the past ten years, to the point where it was virtually scrap yard fodder.

So I often hear my inner voices saying "I'm not worthy".

Thankfully, Troy has forgiven my sins, on the condition that the old girl is looked after properly in future.

[Robsey]

Near side chassis leg is in..
Apparently fitted perfectly after a minor tweak or two.





Sweeet!!

[Colorado]

That will last well. Thing is for you it was bought as a workhorse like mine was. It never occurred to me I would still have it over 15 years later. Mines needed work Not at that level but it's still been welded up here and there. Look forward to seeing updates

[Robsey]

(A brief over view from page one).
The Cav was bought as a Christmas present for the wife 20 years ago.
As my mk2 Cav fell victim to vandalism and rust, I began to use the mk3 for work, piling on the miles at an alarming rate.
It became mine in 2005 after buying the missus a 6 month old Vectra-C.
To complete the mk2 story... sadly it went to the crusher in Nov 2009.

Coming back to today...
The transformation is amazing to see as it progresses.

I suspect by Easter, it will be back at Robsey Villas having it's interior fitted.

A vision that I would never have considered was possible a year ago.

[Lowrider Dave]

Bloody impressive work by Troy!

[Ste]

Excellent work! Amazing amount of time and effort gone into that. Should be ready for another 20 years after all that!!

[vauxhallnutter]

Great work going into this, it will certainly be a nice solid car when its all sorted.

[humbucker]

Top stuff. When do you think the car will be back on the road?

[Envoy CDX]

Jebus! I turn my back for 6 or so months and you go and rebuild a car?!?

[Robsey]

Troy tells me the welding bit will be finished in two weeks.
I think realistically that it will be a month or so.
Then it's off for a paint job.

Back for cutting and polishing

Then I will be joining Troy to sort the few running gear jobs.

I anticipated anti-roll bar bushes and front brakes.

MOT

and then it is back to my house for the interior refit and a partial rewire for the dash and hopefully change the ignition switch and wiring for adding accessory live.

So -as per forum rules - more pictures or it didn't happen.

I popped into Troy's unit last night (Friday).

The front end has been replaced a few times over the years, and apart from strange marking in the paint on the bonnet, the front end is virtually rust free.

Even the power steering pipes in front of the radiator look in perfect nick.

One stripped front end.....
The first picture shows where the carbon cannister is located under the front wing (UK driver's side).

[Robsey]

And another look at the chassis leg welded in and painted to protect from corrosion.

Alignment of the rear beam looks nice and straight.







I dropped off some Reptol solution, and was hoping to drop off some Noxudol 700.

Sadly the noxudol hadn't arrived at work yet.

We did drop off the next batch of cake and biscuits though.

[Envoy CDX]

Epic!

Rob, I have a set of rear discs and hubs here (somewhere) if you want them. Go on, you know you want to!

[Robsey]

Thanks Gary,

I am tempted, just trying to walk before I run.
So much to get through, and I am not very organised.

Still not done the cruise control yet that you have been nudging me to do for five years - ha ha.
Maybe I should get Troy to knock me a mounting bracket up to go near the suspension turret / ABS / Power steering stuff.
Hmm.......... thinks........

[Robsey]

More of Troy's welding -rear arch and outer sill now securely attached to the car






Troy thought that I might fancy a change in career.
So he took the front door off to convert the Cav into a milk float.

I have ordered new door pins and check strap pins for all four doors.

After quarter of a million miles, I think we can safely say that the front door pins were well and truly knackered.

[Robsey]

Door pins arrived very quickly yesterday.

Here are some more pics from Friday evening.
The panel gap between the rear door and the sill and the rear arch are absolutely spot on.

[cavalier1990]

Rust can be repaired.
Its not a big issue

Troy don't mind if i ask about welding on the rear arches; how did you go about joining the outer to inner lip when replacing arches on robsey's motor, is it just plain spot welds? Do you seal up the join as well with panel sealant or something? Trying to pick up a few tips here! I'm not that good at spot welding, need to practice, so going by the little amount of arch lip there is I don't want to blow big holes in the new metal, and have to grind tons of weld down, and make a complete hash of it.

Robsey - sorry for hogging your thread !

Cheers

Andy