89 Astra GTE 16v

Tony22 · 26-05-2007, 08:49

Well the mot has just run out and the tax runs out at the end of this month, so im going to use the opportunity to make a start on the old girl. Just collected the first few bits today, won this boot from ebay at what I think is a bargain price £15, considering its mint. Just the wrong colour lol, also got a new sun roof glass for 50p and lot's of other bits, the seller is a top bloke. Im going back later in the week b4 it goes to the scrappy to cut the complete bulk head out of it and the foot wells.
Well this is the car as it is; it's pretty solid apart from.

* Both rear arches need replacing
* Front bumper is missing washer jets, and has a small crack.
* Rear bumper has gone orange

* Drivers side front foot well has some rust around the drain plug.
* Boot has rusted around the mount for the spoiler. (See replacement)
* Bulk head may need some attention.
* Bulk head sound deadening needs to come off.
* Engine coming out for a good clean and paint, and to give access to the bulk head.
* Sunroof leaks and is seized
* All the front bushes need replacing, or new bottom arms not sure yet.
* And a full repay in vx red

Good points

* Both sills are still perfect not quite sure how.
* Both the engine and gearbox or brakes need no work.
* The inner arches are good.

New Boot cost £15

Im going to do all the work myself so will post up pics to show progress, going to start with the bulk head.

Tony22 · 26-05-2007, 08:56

The above was about a year ago and since then the car has sat out side in the rain and snow, so arches are even worse now, but have been buying more bits to return it to it's former glory.

New quarter panel.

Yesterday I decided to have a proper look over the drivers side this is what I found.

Removed the rear bumper, it's rusty but the inner arch is still there which is surprising.

Removed the rear part of the side skirt, inner arch still present so I should be able to make good with some small repairs to it.

Must be my lucky day one of it's previous owners has filled the sills with wax no rust at all apart from the bit which will be cut out anyway.

Some come out of the drain hole.

Need to decide what to do with the new quarter panel, it's really poor around the light and boot seal.

Should be like this.

May drill the spot welds out and keep the original light surround etc.

**Brett** · 26-05-2007, 09:17

didnt know you were over here too matey!!

Like I said, thats one of the best Astra GTE shells Ive ever seen, considering its not been welded. Superb base for a project!

**CraigGreen** · 27-05-2007, 21:14

That is good! Sills of dreams (for a GTE enthusiast).

Gixer Boy · 28-05-2007, 20:23

Hi There,

I`ve just completed all the welding / panel work on my project 16V.

I had the same issue with the rear quarter Panel.As you suggest I kept the light surround on the car and drilled the spot welds in the lamp arpature. My 1/4 also needed the Door Striker hole reposition and the lugs for the Window trim panel repositioning. I went for a new inner arch lapped and spotwelded to the remaing metal.This made for a better job when spot welding the arch lip .

By the way ,there is an inner panel section near the sill jacking point that has to be drilled / ground off to let the old 1/4 come away.

Hope this helps.

I`ll post some pics soon...

Dave

Wonderboy · 28-05-2007, 20:57

Looks like a nice shell you have there, and an amazing price for it as well.

**Benn** · 28-05-2007, 21:01

very clean sills and bits,
with the archs and bits done she'll be spanking,
very nice car dude,

Dave Dempsey · 28-05-2007, 21:19

As has been said thats a very nice clean shell, suprisng that there are any left as good as that now.

Tony22 · 29-05-2007, 16:57

Cheers for the comments guys, didn't get much time to continue over the weekend pants weather. Removed the rear passenger window, is the seal bonded in??

Tony22 · 11-08-2007, 19:41

Been a while since an update but I have been busy on the astra and an r5 turbo.

Anyway some pics,

Started to drill out the spot welds.

Managed to drill out the rear lamp surround as i'm not happy with the pressing on the new panel.

Pleased I decided to replace the whole panel as there is some hidden rust that I wouldn't have seen other wise. On a plus side there is some inner wing still intact which I can use to repair the rest from sheet steel. Front section of the sill looks like new inside too which is handy, will give all the inner wing a good clean up so I can see what needs replacing.

Noticed that when I removed the panel the door didn't line up after, have to jack the front up a little to bring it back into line, is that normal??

What has been delaying my astra progress.

***Tom Williams*** · 11-08-2007, 19:48

ooh looks nice, i like the r5 too

SteveM · 11-08-2007, 22:27

looking good

awesome pictures as well

slappycarp · 13-08-2007, 19:09

looks really nice mate,
i so much miss me f plate gte : - (

**Benn** · 13-08-2007, 19:33

brave man,
looks good to dude,
and the door droped cause the pin is in the bit you cut off?

Gsi-guy · 13-08-2007, 19:47

nice project car dude!

Lawrence* · 05-09-2007, 22:48

any progress ?

Tony22 · 06-09-2007, 11:55

I have cleaned up the inner wing and made some repairs, will get some pics soon, but i am now a dad so not much spare time at the mo.

On Tuesday 22/8 at 5.28am Hayden was born by emergency cesarean, both Mum and Haydon doing great.

Proud Nan in the pic.

Tony22 · 18-10-2007, 18:22

Mini update not had any time to work on the astra since the birth of my son, but need to get cracking on it as im going to take car allowance and give back the company car.

Started of by removing the rest of the bottom section of the sill, found the sill strengthener to be pretty rotten.

Only really had time to make a repair section for the end part of the sill.
Before

Made a card template, and then cut it out.

New peace welded in.

Then some red oxide to keep the tin worm at bay until it's all sealed up.

That’s it for now, hoping the weather will be ok tomorrow as I want to finish the strengthener and sort out the rest of the inner arch.

Tony22 · 19-10-2007, 18:52

Only managed an hour on it today, but sorted the sill strengthener, going to take some time off work to get the new wing back on.

Cut out the rot.

New plate ready to weld in.

Should give it some strength.

More red oxide.

SteveM · 19-10-2007, 19:12

Quality Pics

Looking good mate

bowman · 19-10-2007, 19:22

good to see another gte getting saved! good work dude.... I think hadrian do a inner arch repair panel....might save you a bit of time....

**Benn** · 19-10-2007, 19:22

Looks good dude,
and congrates on your son comming.

KeithRobinson · 19-10-2007, 19:35

Good work

Tony22 · 21-10-2007, 16:12

Had a spare half an hour, so I thought I would attack my new quarter panel with the spot weld drill bit.

Wasn't happy with the rear lamp surround so of it comes.

DanDare · 21-10-2007, 18:46

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