Troy's btcc replica gsi

Show off your pride and joy! All Mk3 Cavaliers are welcome (please post only one thread per car)
User avatar
Robsey
Club Admin
Posts: 10569
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by Robsey »

Excellent job - Again !! :cool 8-) :)

No wonder you can't wait for your MOT, looks like it will walk the test for many years to come.

I am never a fan of the dreaded test, as I always expect a fail sheet.

I am simply too lazy / strapped for cash to put in the effort that you prove can produce fantastic results.

Suppose I should hang my head in shame :cry:

But I'll say it again - fantastic professional job.!!
User avatar
btcctroy
Mk3 Cavalier Rust Buster
Posts: 3760
Joined: Wed Feb 11, 2009 10:27 pm
Location: Oldham

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by btcctroy »

Robsey wrote:Excellent job - Again !! :cool 8-) :)

No wonder you can't wait for your MOT, looks like it will walk the test for many years to come.

I am never a fan of the dreaded test, as I always expect a fail sheet.

I am simply too lazy / strapped for cash to put in the effort that you prove can produce fantastic results.

Suppose I should hang my head in shame :cry:

But I'll say it again - fantastic professional job.!!
thanks for the kind comments, the reason ive gone down this road is the fact i like my cavalier and want to enjoy many more years out of it.

once rust attacks the body sooner or later you end up chasing it

anyhow more pics soon, hope people like what they see.
....with a brew and my favourite biscuits.
User avatar
Envoy CDX
Club Admin
Posts: 9652
Joined: Sun Sep 23, 2007 3:51 pm
Location: Jarrow, Newcastle Upon Tyne

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by Envoy CDX »

Looks outstanding, very impressed. I'm sure your proud of the result :mrgreen:
Let's see that green sheet soon ;)
Check the Rules!

Raw 8v Power! - Bad Cav, Naughty Cav... Cav want's to do 90!

The How2 Index
User avatar
btcctroy
Mk3 Cavalier Rust Buster
Posts: 3760
Joined: Wed Feb 11, 2009 10:27 pm
Location: Oldham

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by btcctroy »

Envoy CDX wrote:Looks outstanding, very impressed. I'm sure your proud of the result :mrgreen:
Let's see that green sheet soon ;)
and thankyou, still have a lot to do though
....with a brew and my favourite biscuits.
User avatar
Envoy CDX
Club Admin
Posts: 9652
Joined: Sun Sep 23, 2007 3:51 pm
Location: Jarrow, Newcastle Upon Tyne

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by Envoy CDX »

sriguy wrote:
Envoy CDX wrote:Looks outstanding, very impressed. I'm sure your proud of the result :mrgreen:
Let's see that green sheet soon ;)
and thankyou, still have a lot to do though
Nothing to thank me for, your doing all the work :)
Check the Rules!

Raw 8v Power! - Bad Cav, Naughty Cav... Cav want's to do 90!

The How2 Index
User avatar
btcctroy
Mk3 Cavalier Rust Buster
Posts: 3760
Joined: Wed Feb 11, 2009 10:27 pm
Location: Oldham

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by btcctroy »

bit of an update here i've now finished the rear underside of the cav. i just need to spray used deisel engine oil into the chassis for the winter protection.

the cav was booked in for an mot bout 4weeks ago and failed on wiper blades the 2 bulbs. so nothing major there i have my mot for another year.

also i fitted the vectra gsi half leather recaros and rear seats to the cav. turned into an epic with the amount of welding and fabrication required.
i must say the vectra seats in the cav look amazing so really pleased with the results. as nothing on my car is original thought doesnt matter if the interior isn't.

needs a really good clean inside and out, paintwork outside is very rough but should be getting respray next year so doesnt really matter. i'm gonna try and polish her up the best i can until then.

pics to follow
sriguy is online now Add to sriguy's Reputation Report Post Edit/Delete Message
....with a brew and my favourite biscuits.
User avatar
btcctroy
Mk3 Cavalier Rust Buster
Posts: 3760
Joined: Wed Feb 11, 2009 10:27 pm
Location: Oldham

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by btcctroy »

this is a pic under the back. it doesnt look that special but there is no rust to be seen anywhere
Attachments
cav.JPG
....with a brew and my favourite biscuits.
User avatar
Envoy CDX
Club Admin
Posts: 9652
Joined: Sun Sep 23, 2007 3:51 pm
Location: Jarrow, Newcastle Upon Tyne

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by Envoy CDX »

Looks excellent :)
Bet your really proud of the end result :) :mrgreen: :mrgreen:
Check the Rules!

Raw 8v Power! - Bad Cav, Naughty Cav... Cav want's to do 90!

The How2 Index
User avatar
btcctroy
Mk3 Cavalier Rust Buster
Posts: 3760
Joined: Wed Feb 11, 2009 10:27 pm
Location: Oldham

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by btcctroy »

Envoy CDX wrote:Looks excellent :)
Bet your really proud of the end result :) :mrgreen: :mrgreen:

hopefully it should last at least another 10 years.. i am pleased with it still got a lot to do though. 2011 now i guess
....with a brew and my favourite biscuits.
User avatar
btcctroy
Mk3 Cavalier Rust Buster
Posts: 3760
Joined: Wed Feb 11, 2009 10:27 pm
Location: Oldham

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by btcctroy »

more pleased with the interior cdx black carpet with vectra seats looks awesome
....with a brew and my favourite biscuits.
User avatar
Envoy CDX
Club Admin
Posts: 9652
Joined: Sun Sep 23, 2007 3:51 pm
Location: Jarrow, Newcastle Upon Tyne

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by Envoy CDX »

sriguy wrote:more pleased with the interior cdx black carpet with vectra seats looks awesome
And you haven't put pictures up why? :p
Come on, more pics!

I want to do a Vectra interior conversion but not 100% sure on the best approach yet. :cry:
Check the Rules!

Raw 8v Power! - Bad Cav, Naughty Cav... Cav want's to do 90!

The How2 Index
User avatar
btcctroy
Mk3 Cavalier Rust Buster
Posts: 3760
Joined: Wed Feb 11, 2009 10:27 pm
Location: Oldham

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by btcctroy »

i'll get pics tomorrow mate, its a lot of work to get em to fit properly took me a whole day to do the fronts. you need to weld the cav rails to the vectra seats. the driver seat is easier than the passenger. i had to fabricate every bracket for the back seats so theyd work. might be easier on a hatchback though.
if you get the seats i'd help you fit em if you want
....with a brew and my favourite biscuits.
User avatar
Envoy CDX
Club Admin
Posts: 9652
Joined: Sun Sep 23, 2007 3:51 pm
Location: Jarrow, Newcastle Upon Tyne

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by Envoy CDX »

sriguy wrote:i'll get pics tomorrow mate, its a lot of work to get em to fit properly took me a whole day to do the fronts. you need to weld the cav rails to the vectra seats. the driver seat is easier than the passenger. i had to fabricate every bracket for the back seats so theyd work. might be easier on a hatchback though.
if you get the seats i'd help you fit em if you want
cheers, the more info the better :)
Check the Rules!

Raw 8v Power! - Bad Cav, Naughty Cav... Cav want's to do 90!

The How2 Index
User avatar
btcctroy
Mk3 Cavalier Rust Buster
Posts: 3760
Joined: Wed Feb 11, 2009 10:27 pm
Location: Oldham

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by btcctroy »

from memory this is lol.

the driver seat:-
remove base from cav seat 4 bolts.
cut of the height adjuster assembly
there's 4 legs on dowel bearing (height adjustment) the top section of the seat base needs to be removed so 4 legs remain.
the vectra seat needs the bottom section removing at the dowels.
bolt the base in then align the seat for best position mark.
if i remember the fron legs need welding together and the back to the adjusting bar.
job done.

passenger seat:-
take a measure from the floor, and each fixings to the bottom of the existing cav seat.
you will need to cut the whole base of the vectra seat but leave enough material to weld to.
i had to weld spacers to the vectra seat so it would align with the cav frame.
take note the passenger base is 2 separate pieces.
using the measurements and adequate spacers should then bolt straight in.

the rear seat.
the bases fit not to bad use bolts and the original pins.
the back sections are tricky especially in a saloon
center bracket i custom made.
the side brackets are a combination of vectra and cavs.
the rear holding pins only just grab. apparently astra ones are slightly longer but unsure
....with a brew and my favourite biscuits.
User avatar
Envoy CDX
Club Admin
Posts: 9652
Joined: Sun Sep 23, 2007 3:51 pm
Location: Jarrow, Newcastle Upon Tyne

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by Envoy CDX »

sriguy wrote:from memory this is lol.

the driver seat:-
remove base from cav seat 4 bolts.
cut of the height adjuster assembly
there's 4 legs on dowel bearing (height adjustment) the top section of the seat base needs to be removed so 4 legs remain.
the vectra seat needs the bottom section removing at the dowels.
bolt the base in then align the seat for best position mark.
if i remember the fron legs need welding together and the back to the adjusting bar.
job done.

passenger seat:-
take a measure from the floor, and each fixings to the bottom of the existing cav seat.
you will need to cut the whole base of the vectra seat but leave enough material to weld to.
i had to weld spacers to the vectra seat so it would align with the cav frame.
take note the passenger base is 2 separate pieces.
using the measurements and adequate spacers should then bolt straight in.

the rear seat.
the bases fit not to bad use bolts and the original pins.
the back sections are tricky especially in a saloon
center bracket i custom made.
the side brackets are a combination of vectra and cavs.
the rear holding pins only just grab. apparently astra ones are slightly longer but unsure
Cheers Troy, I'll have a muck about with this and a couple of other solutions and see what can be devised :)
Check the Rules!

Raw 8v Power! - Bad Cav, Naughty Cav... Cav want's to do 90!

The How2 Index
User avatar
btcctroy
Mk3 Cavalier Rust Buster
Posts: 3760
Joined: Wed Feb 11, 2009 10:27 pm
Location: Oldham

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by btcctroy »

what other solutions have been used for the bracket in the center of the rear seat
....with a brew and my favourite biscuits.
User avatar
Envoy CDX
Club Admin
Posts: 9652
Joined: Sun Sep 23, 2007 3:51 pm
Location: Jarrow, Newcastle Upon Tyne

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by Envoy CDX »

sriguy wrote:what other solutions have been used for the bracket in the center of the rear seat
I think people have dropped the tank, lined up the bracket, and drilled through and nut / bolted.
However, if I go that far I think I'll use a nutsert - As for the side brackets, I think Gaz just bent his into shape?

I have a full Cav to play with so I can dummy run it in smokey then move onto working on my other cav :mrgreen:
Check the Rules!

Raw 8v Power! - Bad Cav, Naughty Cav... Cav want's to do 90!

The How2 Index
User avatar
Robsey
Club Admin
Posts: 10569
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by Robsey »

Looking smart as ever !!

Brilliant work - do you want to do mine next :p

As a side comment, when you replaced your fuel lines, what did you use and where from... mine are shocking and I want to replace them with decent stuff.

I recall you said Stainless PTFE (hopefully PTFE coated stainless steel tubing).

:thumb
User avatar
btcctroy
Mk3 Cavalier Rust Buster
Posts: 3760
Joined: Wed Feb 11, 2009 10:27 pm
Location: Oldham

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by btcctroy »

Robsey wrote:Looking smart as ever !!

Brilliant work - do you want to do mine next :p

As a side comment, when you replaced your fuel lines, what did you use and where from... mine are shocking and I want to replace them with decent stuff.

I recall you said Stainless PTFE (hopefully PTFE coated stainless steel tubing).

:thumb
i had to bin the ptfe pipe, so used stainless steel nitril pipe instead
well the fuel lines were a bit of a pain, not to make but so refix. the existing plastic clips are rubbish so used 8mm stainless p clips.
i used 8mm cupro nickel pipe and copied the pattern
http://cgi.ebay.co.uk/8MM-X-7-5MTR-CUPR ... 2ea2a4e019

are you interested in a drivers full sill. i'll help u with fuel pipes if you like.
....with a brew and my favourite biscuits.
User avatar
Envoy CDX
Club Admin
Posts: 9652
Joined: Sun Sep 23, 2007 3:51 pm
Location: Jarrow, Newcastle Upon Tyne

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by Envoy CDX »

sriguy wrote: i had to bin the ptfe pipe, so used stainless steel nitril pipe instead
well the fuel lines were a bit of a pain, not to make but so refix. the existing plastic clips are rubbish so used 8mm stainless p clips.
.
Did you just use self tappers?
Check the Rules!

Raw 8v Power! - Bad Cav, Naughty Cav... Cav want's to do 90!

The How2 Index
User avatar
Robsey
Club Admin
Posts: 10569
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by Robsey »

When funds allow, I should do both sills properly,

as for fuel lines, I shall hopefully do these before chrstmas, or else Mr CDX will tell me off !!
User avatar
Envoy CDX
Club Admin
Posts: 9652
Joined: Sun Sep 23, 2007 3:51 pm
Location: Jarrow, Newcastle Upon Tyne

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by Envoy CDX »

Robsey wrote:When funds allow, I should do both sills properly,

as for fuel lines, I shall hopefully do these before chrstmas, or else Mr CDX will tell me off !!
No comment. :no :lol:

Troy, did you have much of that copper pipe left over? If so, I'm sure you and Rob could come to some form of arrangement. :mrgreen:
Check the Rules!

Raw 8v Power! - Bad Cav, Naughty Cav... Cav want's to do 90!

The How2 Index
User avatar
btcctroy
Mk3 Cavalier Rust Buster
Posts: 3760
Joined: Wed Feb 11, 2009 10:27 pm
Location: Oldham

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by btcctroy »

Envoy CDX wrote:
sriguy wrote: i had to bin the ptfe pipe, so used stainless steel nitril pipe instead
well the fuel lines were a bit of a pain, not to make but so refix. the existing plastic clips are rubbish so used 8mm stainless p clips.
.
Did you just use self tappers?
no i drill the use fitting out and used dome head 16mm stainless bolts with a domed nut so it looks pretty lol
....with a brew and my favourite biscuits.
User avatar
btcctroy
Mk3 Cavalier Rust Buster
Posts: 3760
Joined: Wed Feb 11, 2009 10:27 pm
Location: Oldham

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by btcctroy »

Envoy CDX wrote:
Robsey wrote:When funds allow, I should do both sills properly,

as for fuel lines, I shall hopefully do these before chrstmas, or else Mr CDX will tell me off !!
No comment. :no :lol:

Troy, did you have much of that copper pipe left over? If so, I'm sure you and Rob could come to some form of arrangement. :mrgreen:
i don't think i have much left. you need enough to make 3 pipes depends whether it has the same fuel set up as mine. is yours injection
....with a brew and my favourite biscuits.
User avatar
Robsey
Club Admin
Posts: 10569
Joined: Fri Dec 12, 2008 1:42 pm
Location: East Manchester

Re: Troy's SRI 16V gsi replica W.I.P (rust wipeout time)

Post by Robsey »

Yes, it is the 1.8 CFi, with two fuel lines (to the engine bay and the return line)

So I would estimate about 6 or 7 metres plus...

I don't mind buying some tubing - just I have been so impressed so far by your standard of work, that I wanted to work to your good standard. :thumb
Post Reply