1994 Cavalier LSi C20NE (was C18NZ) Work-horse

[Robsey]

No worries - I post up these pictures to give incentives to others.

I know Troy puddle fills his welds to replicate a spot weld.
(Drills a hole through one skin and then fill the hole with molten metal to join to the skin below).
He tells me that his technique is to weld as cool as possible, so as not to blow holes through everything.

Troy paints both sides of each panel with weld-through high zinc paint.

and when finished, he paints over with a thick sealant paint.

There are plans to paint over with another coating like underseal paint / truck bed liner called UPOL Raptor and all box sections and cavities will be sprayed with Noxudol 700 cavity wax.
When it eventually arrives.

I think that is the agreed plan.

Oh -and after a coating of truck-bed paint on the cabin floor there will be a blow over with body colour to give an original look.

The overall effect should be to look factory original, but with a much tougher long lasting level of rust prevention and protection.

[humbucker]

Great progress there. At this rate, you and Telegram Sam should be in possession of two of the most solid Cavaliers left!

[Robsey]

Hopefully we shall see at Billing.

Fingers crossed that I actually get there and it doesn't get flooded.

More bits arrived today - Vauxhall original check strap pins arrived.
They are like short stubby door pins.

Hopefully the doors will be a "solid" fit just like the body shell itself will be solid.

Here are my door pins that I received on Saturday morning.

part number 90 518 425

[Colorado]

have you got a part number for the checkstrap pins? Looking good by the way!

[Robsey]

Thanks.

Try item 8 on the page in the link.

Part numbet = 90 195 523

http://ecat24.com/opel/catalog/part/1/3 ... 8939,8938/

[Colorado]

lovely thanks think mine are well past it

[Robsey]

Here you go - just to confirm what the little fat blighters look like. And the part number is to the left.

[Robsey]

Finishing off the nearside sill and rear arch.







I am sure that Troy is going for the ultra-light weight look.
Now both doors are missing.

Nice welding and dressing. Sweet.

[Colorado]

thats really nice. when you open the rear door its going to look lovely, all that shiny new paint

[James McGrath]

Truly stunning work. The attention to detail is top notch.

[Robsey]

Indeed -Stunning it is.

I am just preparing my side of the stuff.
Mechanicals and running gear.

Just ordered new dampers, springs and the front strut mounting kit including bushes and bearings.

Strut top kit is Febi Bilstein -so OEM.
Dampers are Bilstein B4's all round and
the springs will be Spax SSX 40/30 lowered springs.

I am awaiting Greig SRi's suspension legs, and will strip them ready for shot blasting and stove-enamelling / epoxy powder coating.

Now then - what colour to get my sub frame, suspension legs, rear trailing beam and anti-roll bars and maybe the front callipers all powder coated.?

The springs will be red - no choice in that.
What do you reckon for the rest.?

Black?...
Hmm - not looking for a chav look or demon driver.
Aiming for smart but modest.

[James McGrath]

I would say black but if you're looking for something different and modest then how about a dark or military grey?

[btcctroy]

Id say silver

[Robsey]

Id say silver

Hmm - interesting, wouldn't that be a bit too bling? - lol

I was thinking of doing the alloys in silver or aluminium.

Returning to the underside stuff -
I think only the struts will be "that" visible to anyone that I don't drive over.

So maybe I could get away with Silver....
any more thoughts?

I thought possibly some red to match the springs..

I am expecting Humbucker to say bright yellow like some of the bits on his MV6 - lol

[joe cavalier sri]

Id say silver

Hmm - interesting, wouldn't that be a bit too bling? - lol

I was thinking of doing the alloys in silver or aluminium.

Returning to the underside stuff -
I think only the struts will be "that" visible to anyone that I don't drive over.

So maybe I could get away with Silver....
any more thoughts?

I thought possibly some red to match the springs..

I am expecting Humbucker to say bright yellow like some of the bits on his MV6 - lol

A nice metallic black

[Robsey]

Hmm - I am getting some thoughts on this.

I think I will keep you all guessing until the big reveal - lol

[Robsey]

Oh eck - more chuffing rust.

This time it is in the petrol filler orifice.

You can make a list of everywhere that Cavaliers rust.
I guarantee it, that every place on the list has been rusty on my old girl.

Sorry Troy

[cavalier1990]

Snap !

[Robsey]

Yes indeed - ha ha.

For a change - it is planned that I will be working on the Cav on Monday evening.

Stripping off the front suspension, brakes, anti-roll bar and sub-frame.
Ready for stripping and cleaning.

Hopefully I will not get in Troy's way.

I suspect that he will be working on the driver's side chassis rail that evening.
So he should be at the rear of the car.

[cavalier1990]

Full respray when you're done ?

[humbucker]

I am expecting Humbucker to say bright yellow like some of the bits on his MV6 - lol

I was gonna say a solid grey might look good. But yellow sounds good as a backup plan, hehe!

[Robsey]

Another Humbucker type moment.

Shiney new parts - yayy!!

(This is only half by the way - I did get enough for all four corners)

[humbucker]

Yay! Can't beat shiny new parts!

[Robsey]

Full respray when you're done ?

Yup -that's the plan

Should look pretty much like a new car.

[Robsey]

The last batch of suspension parts.

The top bearing, bump stop and rubber bush. As in the previous photos.
This is one set... second set still in the box.

Due to lack of space at home, I have started stacking boxes of parts by my desk in the office at work.
(I am sure they won't mind -lol )