My Astra Sport - GSi Turbo rebuild.

[rc]

tastey

[c20letTim]

Very nice!!! Indeed, dewis is certainly the man for the inlets, hes in the process of making mine now! Keep up the good work.

[seanr28]

Very nice!!! Indeed, dewis is certainly the man for the inlets, hes in the process of making mine now! Keep up the good work.

Yes his welding is very good, cant wait to get it running!

[seanr28]

got my thorttle body back, after being bored out a bit with new shaft, butterfly etc, now 68mm, was originally 64mm







some new petrol tank straps and TB gaskets





PLastic rivits for arch linners etc



Inlet now part built up





Now using an RX7/8 inlet temp sensor as it reads much faster than the standard vauxhall one!

[seanr28]

Another trial fit with fuel lines and rest of pipework

[DrewyCoupe]

nice car mate defo some good work

[rc]

inlet looks the tits

[seanr28]

a few more bits today, finally got all the bits to remove ABS unit, -3AN fittings etc

[seanr28]

Been a while once again, but a small update

Managed to get another carello (Genuine GM headlamp for passenger side) as the one I had was manual adjust and driverside was electric. Anyway got it fitted and it looks different!






Finally got my Tial Bov mounted! Used Durafix to weld it on!





And finally changed the driver side wishbone for Genuine GM one, as the ones I was using were not GM ones and the cars geometry was always out by some!

Passenger side to do next! and get it running...........again.

[lee303]

that durafix stuff rocks! must get some more for the garage, bet you cant wait to get it running

[seanr28]

that durafix stuff rocks! must get some more for the garage, bet you cant wait to get it running

It does, but its not easy trying to get something like that done well, as being alloy it all heats up and then areas you get perfect then get too hot and run! Did take a while TBH.


Yes its been over a year now since the the rebuild and spec is much higher, should be good for around 450bhp ish.

[seanr28]

Once again, its been a while, thats what happens when you have 2 kids!

Anyway, finihsed fitting the Genunine lower wishbones and new drop links.



Removed ABS unit, as I sick of the bloody thing giving me problems.....



Also fitted a brand new Master Cylinder and started to modify pipe work for use without ABS unit.





Its not yet finished, just mocking up at the minute....

[seanr28]

Rear caliper were shot, so that have been completly stripped, cleaned and fully re-built using new seals throughout and then treated to some proper caliper paint









All usuable old rusty parts were left in white vinagar over night and gave some good results.....

[seanr28]

A bit more progress, brakes done, just need to be filed with fluid and checked for leaks and then fixed into position around the bulk head! hopefully there will bo none.

Rears completed, fully rebuilt.



Inlet finally fitted, along with injectors, fuel lines etc and part of the engine loom





Bracket made for Sard FPR

[Rick Draper]

Looks good but does the throttle operate ok?

[seanr28]

It would appear to be ok yes...

[dewismotorsport]

Looking good Sean some nice progress there! Glad I could help you out with your blonde moment yesterday

[gazturbo]

Great work mate, Does the throttle cable bracket not have to be moved for the angle of the throttle body.

[seanr28]

Finally got my removable slam panel finished....well almost!







Throttle cable is fine, moves nice and freely!

[mikeastra]

has this car been finished?

[seanr28]

Not yet, dont get the time these days!

Have a week off work soon, so will hopefully get finshed very soonn, else its being broken!

[seanr28]

More progress

Car now almost fully back together..

MSD Coil now mock up mounted! Another bracket to be made out of Alloy or stainless at some point.









Engine loom tidy...err.....



Modification to the front ended was needed






Front end complete

[Daz H]

That looks lovely great work!

[mikeastra]

good to see some more progress being made

what top mounts (suspension) are you using??

cheers mike

[seanr28]

good to see some more progress being made

what top mounts (suspension) are you using??

cheers mike

Top mounts, good question you should find the answer somewhere in this thread. Was so long ago now I really cant remember where i got them from, they are solid though....may have been Compbrake.