78 Kadett C Saloon - V8 turbo.

[CR500Dom]

Nicely done sir ;D

I still have similar to do to mine to finish it off

But thats given me some ideas, cheers

[countvauxalot]

Thanks Dom hopfully it should turn out ok.

Out of interest does anyone have any inspiration for a hydraulic clutch pedal assembly? I have a few ideas and wondered what others have used?

[CR500Dom]

Jan 30, 2012 14:19:27 GMT countvauxalot said:

Thanks Dom hopfully it should turn out ok.

Out of interest does anyone have any inspiration for a hydraulic clutch pedal assembly? I have a few ideas and wondered what others have used?

There was some neat stuff I saw on Total Opel in one of the Manta projects I think ?

I just went the whole hog and bought a reverse mount Wilwood pedal box..... (About £150 I think)
That way you have Hyd clutch and bias adjustment on the brakes, along with a clean engine bay and in my case, a lot more room for an exhaust, in your case, a lot more room for the plenum

[countvauxalot]

Hhhhmmmm this could be an option >>>>>>goes to look at floor mounted pedal boxes

[CR500Dom]

Jan 30, 2012 17:00:50 GMT countvauxalot said:

Hhhhmmmm this could be an option >>>>>>goes to look at floor mounted pedal boxes

Its Overhung reverse mount.....

I had to use a 5:1 ratio due to the false floor in mine, but you could probably fit the 6.25:1 ratio in yours with a standard floor ?

www.rallydesign.co.uk/product_info.php?cPath=562_580_595&products_id=4073

[CR500Dom]

Just a couple of pics to show you what I had to do on mine..







Dexion is only there to position it in the car
Still need to finish it but seeing what you have done up there is a big help

[countvauxalot]

Very interesting, thanks for those pics too

[countvauxalot]

Ah look what arrived today thanks Coggers!

[coggers]

A pleasure !


You see , DHL can get it right - when they want to . .

[countvauxalot]

They did a fine job and it wasn't battered to fook!

[coggers]

S'funny , I made sure it was when it left here..!

[countvauxalot]

Update from today - The quest continues

This is the temp in the workshop after 10 mins of the heater being on!



Anyway despite the cold i did get on with a few bits. Here is the new auto gear box tunnel extra girth included





Its to go here







I uncovered the spot welds (as they were covered in black sound deadening sh!t)



and removed them





Leaving this



and a nice overlay template



I removed the front seats at this point so i could get this in here. Its large enough to cover the original tunnel!



After some measuring and messing around i riveted the 'template' in plate ready for some grinding





Anti destroy the windows with grinding sparks tent erected inside the car



The got brave and cut a fook off hole in the floor!



Double trouble, check out the new girth!







I tried the two tunnels on the gearbox



Much better



The auto tunnel fits a treat in its new home





In preparation for fitting the new tunnel i decided to attack the sound deadening inside the car





This stuff is horrible



I find a heat gun and a sharp scraper are best for removing it



getting there, removing it is quite satisfying







I set at the black cr@p on the new tunnel too





a wipe over with white spirit and these sticky remains will come off



flipped it over to deal with the huge bead of seam sealer around the edge



Gone





Then got the engine back in the car again



much easier to get at the box now



got the whole lot sitting right



Then (here's my theory) i set the Gauge to 4 degrees of level and adjusted the angle until the bubble was were it needed to be measuring of the square face of the front of the engine. This way the box output flange should be facing down by 4 degrees.







Leaving the box sitting like so





i laid the auto tunnel in place with the box fitted and it covered it! You can just about make it out here



and i have around 60mm of clearance up front above the cross member - custom sump me thinks



Thanks for looking

James

[countvauxalot]

I'm on the hunt for a Corsa c clutch pedal if anyone has one? Although I've had not time on the car today I should get the engine mounts sorted thus week

[countvauxalot]

I may be getting a bit a head of myself here as you do but I was thinking something like these for the seats (I don't know the cost yet either so that could play a significant part!)



Only in this style of seat as I want harness holes

[countvauxalot]

Some progress from tonight

now the engine and box are were I want them to be its time to make them a more permanent fixture, however that's not as simple as just make the mounts. I need to alter the mounting position as the rubber part of the mount is sitting too high.

I want the rubbers lower



So the angle of the triangulation off the block is more suited to its purpose





Here's the mounting point on the cross member from below



chopped the top off to the desired height





as well as lowering the mounting point I also wanted to move it forward while I was there, in doing this the mount was coming closer to the steering race so I had to take that into account.

Anyway here's my efforts

I found a piece of pipe with a similar radius to the steering rack to use as a template



I started with a small piece of box section



then chopped this area out





Then chopped some more of the original mount away



for a trial fit



I then shaped the top of the new piece of mount to suite the angle of the original mount



and cut a small section out to clear a suspension mounting bolt



and filled the bottom of the new piece of mount in







welded it up



and cleaned it off







Another trial fit - reasonably happy with that



Then started on the top of the cross member mount





that plate will take the rubber mount, as so



and the plate will sit as so on the new piece of mount when its welded to the original cross member - simples!





that's all for tonight

James

[PhoenixCapri]

Coming along very nicely, engine mounts are looking good

[countvauxalot]

Thanks Phoenix i'm hoping to try and get the mounting all sorted this weekend

[snott]

Your exactly the same place i'm at. I've been having right trouble working out how i'm gonna mount up the engine. But i was thinking along the same lines as you

[coggers]

Tidy work on the tunnel James

You use a spot weld drill , I use a grinder - that's why your Kadett will end up being miles better than mine .. !


Glad it was of use to someone though , keep it up man .

[countvauxalot]

Feb 8, 2012 21:48:11 GMT snott said:

Your exactly the same place i'm at. I've been having right trouble working out how i'm gonna mount up the engine. But I was thinking along the same lines as you

Well i hope you know what your doing because i havent got a clue lol

Feb 8, 2012 23:23:19 GMT coggers said:

Tidy work on the tunnel James

You use a spot weld drill , I use a grinder - that's why your Kadett will end up being miles better than mine .. !


Glad it was of use to someone though , keep it up man .

Cheers Mate, the tunnel should work well again thanks for sorting it so quickly ;D