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Dave b's VXR Powered Gsi Diary

DavebGsi

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So I haven't updated this in a while, not because I haven't been working on it, but because I am in the middle of about 10 half finished jobs haha.

So i'll post what I can!

Got the roof flatted and polish and ceramic coated




Also Decided to touch in the stone chips on the front, I always think touching in stone chips looks a bit naff, but actually with 2k mixed in a pot and a tiny brush, flame red lends it's self very nice to blending the stone chips back in when touched in and to be honest, standing 2 foot away, you can't see them anymore so i' glad I did it!

before




after



(insert picture of front bumper and I forgot to take one!)

Next up, got the silent coat soundproofing out and started sound proofing some stuff, roof and rear quarters. Inside the rear quarters was the factory foam recycled material stuff that is all over the mk3, but unfortunately, year of underseal and arch repairs ment alot of this was melted, been on fire or covered in underseal. It took a long time and was very messy but with the thinner and a rag, I finally got it all off and with a fresh inner quarter, placed the silentcoat sheets on it.





Finally spare wheel well, dry and stop the subwoofer from rattling and kill some exhaust noise.... like.... a tiny bit probably lol.




Next, wet flatted and polished the tailgate





went through on the edge which sucked, but hey, ill touch that in

 

DavebGsi

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So the shiny new tailgate was fitted, treated it to some new gas struts, luckily the OE struts are labelled up as 300nm struts, so I was able to order some new shiny versions, these had big balls in comparison! The old ones were obviously gettin tired, but the window isn't fitted yet so i dare say these will be perfect.



Now this next part it was time to get the big balls out. For some reason, i never really concentrated on the fact my brand new tailgate didn't have the rivets for the black panel... :dohslap:
So i toyed with the idea of bonding the panel on, ill thought about this for weeks, no exaggeration! In the end I decided that would be bodge and I was being silly so I decided to get the big boy pants out and do it.

Luckily I never binned the old tailgate so I had that for reference measurements. And don't forget the hole for the bolt that screws into the panel to support the handle which is molded into the panel.




Taped up the new tailgate for marking and so I don't scratch it



drilled alot of holes! Before fitting the rivets I painted the inside of each hole with 2k paint and while the paint was still wet, I fitted the rivet so the rivets and paint would seal the hole as one! Doing everything I can to make sure there is no chance of rust. I then painted around the rivet inside and out aswell.




cut some squares of helicopter tape and put them over the number plate fixing holes, as if I would be screwing a number plate to the car :lol:



Just need to run the mop over the tailgate, refit the clips and ceramic coat this bad boy. So I dug out the black panel



It would appear I got a bit heavy handed 3 years ago removing the number plate lol, That needs painting :doh:

Finished the day off with some sound proofing

 

rickisgrate

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Great work, I'm still on the hunt for a new tailgate for mine but having no luck at all.
 

DavebGsi

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Great work, I'm still on the hunt for a new tailgate for mine but having no luck at all.

They had another one, brand new genuine tailgate, non gsi.

But the postage was crazy haha
 

joycey

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Dave did you remove the boot panel with a shovel lol? :lol: Looking good though :thumb:
 

DavebGsi

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Dave did you remove the boot panel with a shovel lol? :lol: Looking good though :thumb:

:lol: I can only imagine I did!!! I must of had the right arse haha
 

DavebGsi

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So the weather went a bit randomly warm didn't it.... sod it, outside painting time!





Actually got a really good finish on all of it, but the black boot panel has 2 epic runs in it haha. May have to spray it again lol But the roof rails came out really well, brand new clips and fitted..




also did a bit of satin black, the boot button plastic which sits in the middle of the panel



and the aerial base, I had to get the one with an angle grinder and ended up creasing the roof. Luckily the new one covers the ripple in the roof. Thank the lord! Got this from Kev_mk3 , cheers!



Finally, time to change the filter sock on the bottom of the fuel pump. When i got the tank powdercoated, it got filled up with sand and I spent forever gettin the sand out of it. Well, I knew there would still be some lerking in the tank. So I left the old sock on the in tank uprated fuel pump and let it work its magic, filled the tank and as it gets lower, the sand will natural be sucked towards the pump and then get stuck to the sock. So lets have a look....

Inside the tank, all clear! There was a tiny bit floating around but probably normal to be honest! These little bits were all in the pick up tray aswell :) done it's job! Sucked them out with brake bleeder.



The filter





That's a lot of sand! Super impressed! Has done it's job nicely and kept everything out of the rest of the system, The inside of the sock is clean which is good and the gauze on the bottom of the pump.
So i have ordered a new sock and I may check it again in a couple of thousand miles. Good to see my fuel system design worked though, left the wiring long enough you can take the pump right out and put it in the back of the car and the AN fitting slides nicely out the way. I just need to pull the chassis upwards a tad more as the fuel line touches the body and I don't like that!
I'll sort that when the sock turns up.
 
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Kev_mk3

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looks mega and no worries on the Ariel gasket. I knew some random things I have would come in handy one day lol
 

DavebGsi

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So my new filter arrived



It was when I was refitting the pump, the rubber gromit for the wiring jumped out. On closer inspection, it turns out the gromit has already been melted by the fuel, or at least fallen apart.... This was a fuel resistant gromit.... Not so much it would seem! I will have to deal with that further down the line. How boring. Think I am going to need a proper bulk head style plug. which will help with taking the sender out, just need to find something suitable



Small update, after forever someone finally makes short plates in the pressed metal plate style! Celebration times!




All road legal with the reflective-ness and markings






Making proper use of the RC mod!

In other news, started flatting the passenger side today, all flatting done ready for the polisher


 

DavebGsi

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Bit of an update, I've always wanted another boot light in the astra, proper random I know but always thought the OE one was too small and cause I have a nice boot build, I want to show it off lol.
Now U can't actually cut the shell in the same place but on the other side, cause that is where the fuel filler panel is! So the other option is a stick on LED



cut down the back of the lamp so its doesn't hold a bulb, but will still clip into the trim



job done



happy with that, next up I had a chap come over who I found on facebook who was willing to fit my rear window to the astra, I could of fitted the window myself, but for the sake of chucking someone some cash, he has all the gear, the sealant, the window suckers etc. I would rather just pay someone and it be right!
After booking him in, I tried to fit the front window trim around the windscreen, turned out the previous person has used to much sealant, and put the window in slightly pissed aswell! So I couldnt get the bloody window seal in!

So i ended up paying this chap to cut the front window out, clean everything, fit the new seal and put the windscreen back in! Nightmare, but all sorted now :)




well happy with that, another piece of the puzzle!

Next up, bluetac on the wing to make where the rivets need to go for the side skirt clips



then just pushed through the bluetac with a pointer to mark the paint and job done. Ready for drilling and rivets.

Next up was polish the quarter, funnily enough started polishing the quarter and noticed this



Must of been where I didn't flat the quarter properly, looked like I had flatted through the orange peel, but missed this bit along the seam, I was probably being too careful as It is near the crease in the quarter and didn't want to rub through!

Also found this where I has scrtched the clear coat with the edge of the stanley blade gettin rid of a run!



So on these areas I went back through the motions of 2000,2500,3000 grit and got rid of them, polished up and second time, much much better!




With that all done, mocked up the side skirts, marked the holes, drilled, painted and then slide the riv nuts in ready for the skirts to go on!



At this point realised I don't have enough Side skirt clips! Annoying! So just trying to track some down!

With the quarter flatted though, I can fit the rear bumper, after some prep.

First things first, heat protection to stop the back box melting the bumper again! Zircoflex stick on stuff, I Melted the bumper, then ran this and it never got any worse so it works!




So to protect my new paint work I bought myself a roll of PPF. Everyone is badgering on about this stuff now days and although I won't be fitting big sheets of it across my front bumper but I bought some to protect certain bits and bobs.
So the first part to fit it to is the 'built in mudflaps' which is probably more of a strengthing part of the bumper to keep its shape, but this part gets pummled with stones and end up black again!

SO cut a sheet off




funnily enough the sheet isn't quite big enough lol

applied the sheet, you can see the texture of the plastic where it isn't smooth from years of stone chips, I never bothered trying to smooth it out of anything, but that no airbubbles, just that textured plastic look.



little cut out for the triangle



used the hot air gun to fold the corners round, waited for it too cool down then cut the excess off with a stanley blade! Actually looks really good from head on, seamless!



Both side done



New foam fitted to the top, no idea why this is on the bumper, but it is so I replaced it for new haha



bumper on with ' as bright as the sun' number plate lamps lol





led tail lights and number plate lights...



their a bit bright haha
 

Kev_mk3

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Have to say looks stunning
 

djwilde69

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I do like the 2nd boot light, what plastic did you use for the mud flaps
 

DavebGsi

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I do like the 2nd boot light, what plastic did you use for the mud flaps
to cover them do you mean? The mud flap thing its self it just a part of the structure of the bumper, pretty sure you know that but just checking lol.

The clear stuff was PPF clear tap stuff, or helicopter tape I call it. This was actually off ebay for protecting mountain bike frames lol. but same stuff!

 

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