1994 Cavalier LSi C20NE (was C18NZ) Work-horse

[Robsey]

Looks like the Cav will not be wearing it's fancy pants headunit and display for the weekend

The lad getting it ready for me has been too busy to do the work that I asked him to do.

Also I have still heard nothing from the powder coaters so looks like the wheels won't be ready either

Hmmm - I will still be doing the VBOA on Saturday, but in more or less standard format.

I will have to see if I can get the car ready for Vauxfest instead - assuming the missus wants to go to another Vauxhall meet.

Updated 12/7/18 at 3:00pm.
Just spoke to Chicago... wheels have not been started yet.
My own fault for taking so long to drop them off.

Car dash is still in bits.
Will have to fit a radio, but will leave the rest unfitted.
My wife cannot last 2 1/2 hours each way on Saturday without music...
My singing voice leaves a lot to be desired.

Eek!!

[Colorado]

At least you get to go to it and enjoy the other cars

[Robsey]

Aye indeed...

Took me about 2 1/2 hours to refit most of the dash.
Bizarrely after 7 weeks of blazing sunshine, Manchester suffered several episodes of torrential rain over the past 26 hours.

I got completely soaked lying on my back in the driver's footwell with my feet out through the driver's door, trying to reconnect my heater hot / cold flap bowden cable.
Alas I got so wet I decided to sack it for tonight.

I also still have the rear screws for the centre console to screw in, and fit the ash tray.

Looks like an early start tomorrow morning to dig out the ash tray, fit the bowden cable and screw down the centre console.

At least I have everything else working such as the cd radio and cd changer, heater blower, windows, lights, fuel computer etc.

(Be interesting to see what economy figures I get running on cruise control for about 70 miles down the M1 tomorrow).

No point posting any photos as the car looks exactly the same as it did 12 months ago.

[Robsey]

I got completely soaked lying on my back in the driver's footwell with my feet out through the driver's door, trying to reconnect my heater hot / cold flap bowden cable.
Alas I got so wet I decided to sack it for tonight.

I also still have the rear screws for the centre console to screw in, and fit the ash tray.

Looks like an early start tomorrow morning to dig out the ash tray, fit the bowden cable and screw down the centre console.

Okay late night update... 12:45 in the morning so I decided to finish off the remaining jobs.

The rear centre console screws were already screwed in afterall.

I fitted the bottom heated seat and traction control panel... nothing wired up.

Fought for ages trying to slot the ashtray into the dash...
Checked the cig lighter socket - all working fine, and fitted the cig lighter itself for completeness.

Last job was to re-attempt to fit the hot / cold air mix flap bowden cable.
Again upside down, on my back in the driver's footwell in the dark.
After 5 minutes of fighting, it all slotted into place. Yayy.

Car dash fitted.
I chose to leave the clear perspex panel off the instrument cluster.
Just looks so much cleaner and tidier without it fitted.





A thought passed through my head this evening.. something on the lines of -
"I ain't stripping all that out again for a long time"
What a total pain.

We shall see. Ha ha.

[cavalier1990]

Car dash fitted.
I chose to leave the clear perspex panel off the instrument cluster.
Just looks so much cleaner and tidier without it fitted.

[ Image ]

[ Image ]

A thought passed through my head this evening.. something on the lines of -
"I ain't stripping all that out again for a long time"
What a total pain.

We shall see. Ha ha.

Pretty neat idea, especially with the digy dash removing the perspex panel. They get all scratched anyway and it looks 'orrible!

[Robsey]

Indeed the perspex gets scratched and is never the same again.

And the Astra Digi-Dash reset rod does not line up with the hole in the Cavalier perspex panel,
So redrilling a new hole to line up with the Astra reset rod makes another major blemish on the perspex panel.

At this point, I should leave the car alone as it looks right... but I cannot see me doing that for long. Ha ha.

Just as a side comment - after having my board computer programmed for a C20NE, the consumption figures at idle have dropped down to a steady-ish 0.3 gal per hour.
(From 0.4 to 0.5).



Thinking of the emissions, a brain wave struck me.
I have not checked the manifold gaskets for air leaks. An air leak after the air flow meter could cause a lean mixture, which the lambda will try to correct by enriching the mix (pumping more fuel in).

So hopefully I will get the manifolds off and fit new gaskets to rule out that as a cause.
And possibly get the emissions and consumption figures reading better.

[ilovedmymantas]

You seem to have found the end of the tunnel at last
Good to see your efforts have proved worthwhile, nothing looks out of place.
That's a high bar you've set yourself with for next years improvements though

[Robsey]

You seem to have found the end of the tunnel at last
Good to see your efforts have proved worthwhile, nothing looks out of place.
That's a high bar you've set yourself with for next years improvements though

The tunnel is never ending. Any Cavalier owner knows that.

As for "next year's improvements"... I plan to have them done by the end of next month.

Although I cannot find the post in which I listed the plans / jobs for August.

As it stands, the car is the closest to standard and complete, that it has ever been in the past 10 or so years.

[Robsey]

Ah yes - found the post.
Due to a brief period where the forum became unobtainable, I saved it until service was resumed.

So here are the jobs to do before VauxFest...
And that will be it except repairs and maintenance... no more silly faffing.

Jobs to do are: -
1 - Fit replacement alarm and immobiliser.
2 - Fit refurbed Fanblade wheels.
3 - Wire in the third brake light.
4 - Replace duff front fog light bulb.
5 - Fit SRi exhaust back box / tail pipe.

Optional Jobs to do are: -
6 - Fit CD70, CID and UHP4 bluetooth unit.
7 - Fit auto lights unit.
8 - Fit new gaskets to both manifolds and camshaft cover
9 - Fit LED bulbs to angel eye rings (16 bulbs).
10 - Fit door card lights
11 - repair rear load area cover.

Enough to keep me out of trouble.

[Robsey]

The prospect of stripping out the 22 year old Meta alarm became a lot easier today.

I managed to locate the wires for the immobiliser part.
This is essential as I need the car to run after the Meta alarm has been removed.

Another quirk was that the alarm used fuse 30 for it's permanent live feed.

So removing fuse 30, causes the immobilser relay to click into the 'immobilised' condition. And then the fuel pump stops running, killing the engine a few seconds later.

Shorting the two immobilser wires together means the car will run regardless of whether fuse 30 is fitted or not. In fact the car will run with the whole alarm unplugged.

Just need to find time to strip out the old alarm and it's wiring.
And
Fit the new alarm via the yellow alarm connector plug up behind the glovebox.

It will be wired as GM intended it.

The new alarm is a Scorpion unit with full alarm, central locking, full closure and immobilser functionality.

Reported to be as good as the Cat 1 Toad units, but about half the price.

As long as it doesn't give false alarms like my Meta unit does, due to ultrasonic sensor issues, and a delayed stray 'unlock' signal a short while after the alarm has been set.
Bit of a pain to put on the alarm and find my doors unlock themselves after 40 or 50 seconds.

I am currently pulling fuse 17 to stop this.

[cavalier1990]

Replacing inlet gasket a good move, i remember mine was toast, it wasn't causing too much of a problem, bit enough for me to notice it wasn't running right. I At first i didn't suspect gasket, but on removal there was bits missing and it was frayed.

[Robsey]

I have done every other conceivable job on the car, so the inlet manifold gasket seems a good thing to consider.

My Camshaft cover is weeping oil too, so may as well go around doing all the gaskets.

Anyway - photo time.

Even more original interior...
Refitted an SC303 that used to belong to James.
Wow the sound is so much better than my VDO MS 4150 sat nav radio.





The only way I could make it more original would be to refit my old dual info display, remove the air con switches, remove the heated seat switch panel and refit the rubber mats.

There is no way I am converting back to standard analogue instruments.
It would be far too involved.

[cavalier1990]

Looks pretty smart, is that GSI/SRI interior, the seats look like sports ones? I could do with a decent interior for mine, something like SRI interior or even just better seats. The bases aren't too bad but the material looking a bit worn now. The seat runners are also a bit wobbly, going to try tightening them up some way while they are out.

[Robsey]

The seats and door cards are Anthracite coloured SRi trim spec items.

They are far from great condition, but a nicer colour than my original grey LS upholstery.
After 18 months of sitting in my shed, the LS upholstery had gone musty and moldy.

I fell on my feet with the timing of the SRi trims becoming available.

They originally belonged to Joe from Rotherham, but he decided to abandon refurbing his SRi and so gave a lot of parts to Troy, including the interior -
the lad who welded my car and did all the bodywork and mechanicals for my restoration.

Troy asked if I wanted the SRi interior for free.
I would have been daft to say no... the rest is history.

Not sure what Joe did to remove the trim from his car, but a lot of hidden damage was found on the front door cards.
Probably why they were free.

A quick clean and it does look quite smart - considering it's prior hard life.


Talking of a quick clean - I cleaned the outside of the car today...
Well it is show season...

[Robsey]

Hoping to get the alloys back and fitted this week.

I rang Chicago Coatings on Friday, and they confirmed that the wheels, discs and shields were done.

No idea when I can collect them due to silly visit and clinic schedules and 2 days at a posture and mobility conference in City Centre Manchester (the old G-Mex Centre / Central Station Conference and Exhibition Centre).

Hoping to get them "rubbered up" very soon, as well as get the SRi back box fitted.

Think I may leave the interior alone now too.
Really liking the sound of the SC303, which also sounds good with a cassette converter plugged in.
Using my old Galaxy S2 as an mp3 player makes a good enough compromise for bringing the sound system into the 21st century.

As for sat nav... my current phone gives up to date free mapping and dynamic routing.

I have a full head gasket set on order plus a throttle body gasket.
Surely there is nothing else left to try in a bid to ensure the best possible emissions and idling fuel economy.

[Robsey]

Well I couldn't keep the wheels a secret any longer.

They need a bit of tidying ( blotchy lacquer).
Definitely different.







Also decided to do a few jobs.
1 - fitted missing bolt to nearside wing at the base of the a-pillar.

2 - fitted a door-card retaining bracket in the nearside front door.

3 - tried to add a wire for the third brake light.
So pulled out the rear hatch loom and found this...



So more electrical repairs.

[3cav3]

Those wheels should look stunning against the dark colour of your car.

[Robsey]

Thanks,
I wasn't too sure about the prospect of having the wheels done in gun metal grey, but it looks nice in the metal.
(Not as chavvy as I was expecting - ha ha.)

As said - the coaters put a lacquer coating on for me, but it does not look even (as in clarity not smoothness), so there are a lot of dark cloudy shadows, so I plan to blow them over with the same paint that I used on my bolts, just to even out the colour.



Just for Info, the craft spray paint from Wilco gives a great metallic gloss finish.

[Mazza]

Damn those alloys look nice!

[Mk3alan]

Nice! I have a similar security key for my Astra wheels and it always seems very 'bendy' in use, thinking of making something similar in metal with perhaps a hex head.

Alan

[Robsey]

The idea of the flexible handle is to stop you over-tightening the bolts.
They do not need to be very tight as the steel bolts will chemically weld to the alloy wheels in time, unless you coat them in coppa-slip or similar.

Basic chemical reaction of two dis-similar metals touching each other.

[Mk3alan]

I never do them up tight, threads copper slipped, all clean and proper - but I usually have one (or more) that 'sticks'
And I fear for the plastic handle!

Alan

[Robsey]

Okay - jobs tonight.

1 - I blew a couple of coats of metallic paint over the centre caps to check that I won't make a dog's dinner of my wheels, when I spray over the patchy lacquer coat.
The Wilko's paint has done a great job, so just leaving the centre caps to bake in the sun for a few days. Before gluing on the griffin badges.

Will paint the wheels in a week or so.

2 - I repaired my hatch loom.
No less than six wires were cracking, but I am not certain if any were preventing current from flowing.
It mainly looked like multiple-cracks in the insulation.
I know my hatch-lock controlled central locking trigger wire was not working, but all else seemed fine.

I cut out all the damaged wiring plus a few extra inches at each end to hopefully avoid future weak spots near the elephants trunk / corrugated rubber hose between the hatch and the top of the rear d pillar, where the wires are flexed back and forth each time you open and close the tail-gate.

All soldered and double heat shrink tube insulated.

As mentioned in my previous post, I also added a wire to feed my 3rd brake light.
The light unit has already been fitted for about twelve months - just not wired in.

It will earth through the tail-gate metalwork just like all the other consumers in the hatch. There is also a fat brown ground wire that links the hatch to the body (inner wing of the load area). One of the dodgy looking wires repaired tonight.

Still a bit apprehensive about getting the rear window demister feed wire back in place.
Looks a very fiddly task to do...
I have a draw cord in-situ ready to pull the main loom back through the near side of the tail gate frame.

I could do with a replacement elephants trunk... mine is holed / split quite badly.
Sadly they are no longer available.

Update Edit - 26_7_2018.
Managed to get a wire from the elephants trunk hole to the window demister hole.

So hopefully just a matter of pulling the wiring back into the tailgate.

No further progress nor repairs today :/

[James McGrath]

Sorry to hear that the trip computer reprogramming wasn't the right one.
At least we'll know for next time.

[Robsey]

Nothing to apologise for James.
I simply gave you the wrong number.

These things happen.

Besides, it is quite nice getting 77mpg and legally doing 142mph on the motorway - tee hee.


Update - 27_7_18.
I have made my cruise control mounting brackets and the paint is now drying.

Hopefully have them installed in the next week or so.