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Dave b's VXR Powered Gsi Diary
- Thread starter DavebGsi
- Start date
Brake servo in with new butamin seal on there
Painted servo and master cylinder in
Got the flexie pipes pipes fitted, 2 new pipes to the master cylinder fitted as I am now running a Calibra Turbo 23.8mm master cylinder.
Then serveral months later, the rest of the flexie turned up, all the way to the rear!
Incredibly close to the fuel line fittings...
But I was able to find a way round it. I had to think about it but the problem was with the fuel line, if I ran the brake line straight to it was going to end up with some pretty tight kinks in the pipe so i decided this was the lesser of 2 evils and made a nice loop radius in the brake line, looks a bit gay, but does the job lol
Passenger side all good though
As people may of noticed, I have binned off the restrictor valve for the rear axle.... This either will or wont effect the car lol. I have kept the ABS so nothing extreme is going to happen. But also the back of the car was so low that the load restrictor was at max anyways, which mean it thinks the car is loaded, so I would of had maximum braking anyways.
If it is constantly kicking the ABS in, i'll look at some restrictors, but i think it will be ok
Painted servo and master cylinder in
Got the flexie pipes pipes fitted, 2 new pipes to the master cylinder fitted as I am now running a Calibra Turbo 23.8mm master cylinder.
Then serveral months later, the rest of the flexie turned up, all the way to the rear!
Incredibly close to the fuel line fittings...
But I was able to find a way round it. I had to think about it but the problem was with the fuel line, if I ran the brake line straight to it was going to end up with some pretty tight kinks in the pipe so i decided this was the lesser of 2 evils and made a nice loop radius in the brake line, looks a bit gay, but does the job lol
Passenger side all good though
As people may of noticed, I have binned off the restrictor valve for the rear axle.... This either will or wont effect the car lol. I have kept the ABS so nothing extreme is going to happen. But also the back of the car was so low that the load restrictor was at max anyways, which mean it thinks the car is loaded, so I would of had maximum braking anyways.
If it is constantly kicking the ABS in, i'll look at some restrictors, but i think it will be ok
Next up, plumbed in the Oil Catch Tank.
Ordered myself some oil resistant, fluro-lined hoses from Roosemotorsport, don't want any oil sweating from my hoses!
Rocker breather, exactly 1 metre long, out the rocker, under the inlet and off to the tank
Secondary breather from the crank case breather tube, 'T'd off and sent to the catch tank too.
Then finally, coming out of the catch tank, the sump return for any oil. The catch tank has an oil seperator plate in it so any oil vapour hits the plate, condenses, then dribbles back to the sump via this return line... if I have built the engine well enough, this should be minimal haha
Ordered myself some oil resistant, fluro-lined hoses from Roosemotorsport, don't want any oil sweating from my hoses!
Rocker breather, exactly 1 metre long, out the rocker, under the inlet and off to the tank
Secondary breather from the crank case breather tube, 'T'd off and sent to the catch tank too.
Then finally, coming out of the catch tank, the sump return for any oil. The catch tank has an oil seperator plate in it so any oil vapour hits the plate, condenses, then dribbles back to the sump via this return line... if I have built the engine well enough, this should be minimal haha
Last little update, My accelerator cable was looking very tired, not sure if anyone else has had this issue, But the plastic coating has gone brittle and fallen off leaving just the metal on show, which had then gone rusty!!
So I did some measuring and order some 4-1 heat shrink! Usually used on wiring to seal connections, this 4-1 shrink was perfect to just about go over the ends of the accelerator cable, but shrink enough to wrap it tight, I did it and it worked perfectly! Gave it a nice smooth finish and looks OE I think!
Just had to fit it which it was still hot which was exciting so I didn't end up with ripples on the inside, but worked a treat!
More to come!
So I did some measuring and order some 4-1 heat shrink! Usually used on wiring to seal connections, this 4-1 shrink was perfect to just about go over the ends of the accelerator cable, but shrink enough to wrap it tight, I did it and it worked perfectly! Gave it a nice smooth finish and looks OE I think!
Just had to fit it which it was still hot which was exciting so I didn't end up with ripples on the inside, but worked a treat!
More to come!
Todd100
Club Member
Nice one mate, I'm not 100% sure but I think your master cylinder is the saab version as the calibra/cavalier one I had was both outlets on the right same as standard
Thats interesting you say this, I have not heard of someone fitting a bigger master cylinder and having to loose the windscreen bottle haha. I know I have the braided lines, but I never realised how close the washer bottle runs to the master cylinder and actually it has a cut out for it! So the washer bottle can't go back in which is a bit of a shame, but i'm thinking i may make one later on possibly. For now though I will be using the headlight washer bottle
b:
I also sound proofed the floor, all the old sound proofing had to come out because of the rust and holes in the floor and spraying etc, so I went with silent coat which was advised to me by TubaMagna8 , cheers for that! The stuff was super easy to fit once warmed up... I had to warm it because it about 2c at the moment!
Can really hear the difference already! It wasn't too bad price wise and easily enough to cover the floor
Can really hear the difference already! It wasn't too bad price wise and easily enough to cover the floor
Hello mate, cheers buddy! I am running the LEH OE oil and water hear exchanger. bolts to the back of the block under the inlet manifold. Seems to do the job, I have only had high oil temps on a boiling hot day at brands once, but i fitted the direnza coolant rad and the oil temps never went that high again so it definatly does the job!
Ah right fair enough thought so, saw the pic of the intercooler and thought theres no room for an oil cooler now haha
So this update has been in the back ground since... well, summer last year haha
A super short version of this story, a mate of mine got screwed over, then the guy got in serious financial bother which was awesome Karma cause he was a C.U.NEXT.TUESDAY
so for the total sum of 300 quid i got a TIG welder!!!
I've always wanted a TIG welder so I could weld Ally, and do awesome looking welds hopefully. Honestly this was a mega deal, the welder, a bottle of gas, a box of ally rods and a box of tungsten rods for the torch. Incredible deal haha. Karma hey
So i didn't touch it for 3 months but in about sept I started plodding along
Built a trolley for it
That's 5.5mm steel, impressively it welded it with ease!
So the first job was to make my boost pipe more attractive in the engine bay, before it did all fit, but a fair amount was taken up in the silicones, this kinda shows it.
So I got myself a new pipe to cut up and made a better shape from it
Right now about 100 hours of youtube, a whole bottle of gas and ALOT of struggling and swearing later I ended up here. I'm not gona lie
Tig welding mild steel =
Tig welding Ally = Incredibley hard!!
An example of mile steel welding... mega tight and neat welds are easy
I cut a pipe into bits and did alot of practice, this was the jig I made
So I welded the pipe, was structual but looked a bit pants, so ground it back and went over it again to give it a better finish, then polished up
Also welded this boss on for my engine pre-heater
Welded some brackets onto my house mates charge cooler Rad so he can hang it from the boot floor lol
Pretty sick mod that
Back on the astra, Welded a new bracket on the dipstick tube, the good think about tig is u can weld very thin metal without blowing through. The dipstick tube was just pushed in the block before, done properly this time. Really happy with this actualy.
Uses a unused boss in the block
Finally, made a new accelerator cable bracket which is in-line with the throttle more compared to the old one.
Now this was tough cause this is welding high grade ally, to low grade cast ally. mega hard
So first of all I just ran the torch along the cast to melt it and make a good base ( all this picked up from watching you tube)
Tac on
The I welded, I ground it back to check it has full penertration..... It did! However it was then very hard to recover from this and ended up making a right bloody mess!
Alot of grinding and welding later, it ended up ok, but with a hole in the side of the bracket
Thats all folks, The TIG welding is tough, alot harder than MIG. But I think this is the nature of ally welding cause of the heat, it makes it tough. But the welds in this post I am happy with, I'm not gona win any awards, but not bad for a beginnner I think! More to come!
A super short version of this story, a mate of mine got screwed over, then the guy got in serious financial bother which was awesome Karma cause he was a C.U.NEXT.TUESDAY
so for the total sum of 300 quid i got a TIG welder!!!
I've always wanted a TIG welder so I could weld Ally, and do awesome looking welds hopefully. Honestly this was a mega deal, the welder, a bottle of gas, a box of ally rods and a box of tungsten rods for the torch. Incredible deal haha. Karma hey
So i didn't touch it for 3 months but in about sept I started plodding along
Built a trolley for it
That's 5.5mm steel, impressively it welded it with ease!
So the first job was to make my boost pipe more attractive in the engine bay, before it did all fit, but a fair amount was taken up in the silicones, this kinda shows it.
So I got myself a new pipe to cut up and made a better shape from it
Right now about 100 hours of youtube, a whole bottle of gas and ALOT of struggling and swearing later I ended up here. I'm not gona lie
Tig welding mild steel =
Tig welding Ally = Incredibley hard!!
An example of mile steel welding... mega tight and neat welds are easy
I cut a pipe into bits and did alot of practice, this was the jig I made
So I welded the pipe, was structual but looked a bit pants, so ground it back and went over it again to give it a better finish, then polished up
Also welded this boss on for my engine pre-heater
Welded some brackets onto my house mates charge cooler Rad so he can hang it from the boot floor lol
Pretty sick mod that
Back on the astra, Welded a new bracket on the dipstick tube, the good think about tig is u can weld very thin metal without blowing through. The dipstick tube was just pushed in the block before, done properly this time. Really happy with this actualy.
Uses a unused boss in the block
Finally, made a new accelerator cable bracket which is in-line with the throttle more compared to the old one.
Now this was tough cause this is welding high grade ally, to low grade cast ally. mega hard
So first of all I just ran the torch along the cast to melt it and make a good base ( all this picked up from watching you tube)
Tac on
The I welded, I ground it back to check it has full penertration..... It did! However it was then very hard to recover from this and ended up making a right bloody mess!
Alot of grinding and welding later, it ended up ok, but with a hole in the side of the bracket
Thats all folks, The TIG welding is tough, alot harder than MIG. But I think this is the nature of ally welding cause of the heat, it makes it tough. But the welds in this post I am happy with, I'm not gona win any awards, but not bad for a beginnner I think! More to come!
Unbelievable work Dave. I love how every little pipe and bracket gets so much care and attention. It's all coming together so well now!
The TIG welding is coming along really well too, I have heard it was very difficult. I'd love to get one myself one day, a handy tool to have for a workshop.
The TIG welding is coming along really well too, I have heard it was very difficult. I'd love to get one myself one day, a handy tool to have for a workshop.
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amazing work Dave true credit to you
TubaMagna8
Club Member
Looks superb that mate, that boooost pipe tho...
Joycey
South Central Co-Ordinator
Awesome work! Love the heat shrink on the throttle cable
Cheer Andy, the main reason I like the TIG so much now I thinkin is cause it's my new toy haha.
But in all seriousness, It doesn't make splatter like a MIG so you can use it anytime without showering everything in sparks!
Looks superb that mate, that boooost pipe tho...
Cheers mate! Yea I'm really happy with how it came out!
Cheers mate, I was actually a little shocked how good it came out! The heat shrink cost about 6 quid with the postage so well worth doing for the improved look