mk1 Cavalier GLS 2000 Project

retrocarclub · 12-02-2008, 23:00

As I frequently visit this site I thought it about time I posted up details of my current project Vauxhall.

When I bought it the car was a completely standard mk1 Cavalier GLS 2000 Automatic and looked like this:

I drove it around for a few weeks but it had a horrible habit of stalling at, or on, busy roundabouts. I never got to the bottom of the problem but I think the awful auto slush box might have been the bulk of the problem. And so I quickly realised that I needed more power and a manual gearbox. Which leads me on to November, when I took a week off work and began transplanting a spare 16v c20xe engine and manta 5 speed manual gearbox into the GLS.

Here's how the car looked when I began...

How the engine looked fresh back from being machined and reassembled.

About an hour in, the disassembly begins!

Exhaust off:

Then I single handedly removed the old 8v... I couldn't get over how long the engine and box where together!

Finally out, I felt like some kind of whaler desperately trying to drag the old lump of pig iron out! :lol:

Sump baffle plate modification so the Manta 1800 sump fits OK.

Then a sudden jump to Wednesday morning because I forgot my camera. Notice anything different?

Trial fitting the manifolds.

retrocarclub · 12-02-2008, 23:08

More pictures:

No he wasn't sleeping on the job, he was fitting and modifying the injection fuel tank.

Work in progress:

I think I definitely need some throttle bodies, look how ugly that standard injection setup is:

Looking good even if I do say so myself!

And thats where I had to leave it for the week.

retrocarclub · 12-02-2008, 23:20

Since then I've bought a set of R1 bike carburettors and ordered one of Tom Reid's excellent bike carb manifolds. I've also fitted most of the Ford Mega Jolt components needed to run the system with the bike carbs and fitted a FZR1000 fuel pump to the boot.

Once I've received the manifold, correct jets and 36-1 trigger wheel I will most certainly be close to having it roadworthy again. I cant wait!

retrocarclub · 12-02-2008, 23:22

You can read the entire build diary here:

http://www.retrocarclub.co.uk/forums...ndpost&p=58966

**RobJenko** · 12-02-2008, 23:31

awesome! love it fella, keep the pics coming!

olix99 · 13-02-2008, 08:31

awsome work fella, should be a bit of an animal in the wet

**Brett** · 13-02-2008, 16:01

Love that mate, keep the updates coming.

its the sort of thing I can see myself doing with either a Mk1 Cav or Manta one day.

novashed · 13-02-2008, 17:18

nice project, nice to see something different, definately deserves an XE, although it still looks dwarfed int hat bay lol (i bet V6 came to mind).

i have the same engine crane as you, tougha s old boots lol.

olix99 · 13-02-2008, 17:59

awsome project, i was thinking the same novashed - V6 would fit nicer might not look so small

unless...LS2 power anyone?

Colonel K · 13-02-2008, 18:12

Mk1 cavs are so cheap right now and so prime for modding.

Yours looks like a proper minter!

astraderv · 13-02-2008, 18:14

I like this long time

ps- don't ditch the old lump/ slosh box- someone will have it off you!!

My dad had a mk1 Cav when I was young, like yours but browner, lol

wazpaz · 13-02-2008, 18:29

brilliant stuff!! me like

Galahad · 13-02-2008, 18:39

Me like that a hell of a lot, proper wolf in sheeps clothing.

Excellent, thought personally i'd have chucked a 3.0 24v Senator/Calrton GSi straight 6 in there!

**Lugy** · 13-02-2008, 18:58

looks really good so far. a mate at work is doing the same conversion with his mk1 cav, though he has an xe manta donor car to make things easier!

got to be a 4 pot in there, they arent heavy cars!

Johnny A · 13-02-2008, 22:04

love it, what exhaust manifold is that? I have the exact same one on mine but didn't find out who made it.

retrocarclub · 14-02-2008, 10:17

Quote:

Originally Posted by Johnny A

love it, what exhaust manifold is that? I have the exact same one on mine but didn't find out who made it.

Glad you all like it! I just cant wait to get it finished so I can have some fun in it!

I chose the XE for simplicity, because I already had a freshly rebuilt one with all the conversion bits left over from another project. Also the weight of the XE closer resembles the weight of the standard block (although lighter) - a 24v 3.0 would have weighed the front down far too much and I've never really been a fan of V6s (they always seem like a lot of hassle for not a lot of gain). Eventually I'd like to fit either a LET engine, which would be nice and easy with the existing conversion parts, or a light weight V8. But for the moment the XE should be good for getting used to the way the car drives with 150+bhp!

The exhaust manifold was from Peter Lloyd Rallying, it was the cheapest 16v RWD manifold I could find (and actually sold for a mk1 Escort), but I took a chance and it fits superbly - much better than the Ashley manifolds.

Also I forgot to mention that I've also got these 16v Astra GTE calipers to go on once I've got my 15" ATS classics from Germany:

They will be fitted to some specially machined group N disks with pre machined alloy spacers to fit my hubs.

GeorgeGt · 14-02-2008, 13:17

Really cool looking carm8. One day i was thinking the same , how to get more displacement under my cavs hood without fitting a big arse v6..... then it suddenly hit me .... vw vr6 comes in 2.8l 2.9l 3.2l and is only little bit wider than my xe

**Add_Gee** · 14-02-2008, 13:28

Cool build, keep us up to date.

Jack · 14-02-2008, 13:47

Awesome build! Are the engine mounts different on an XE to the standard engine?

And you've used a Manta gearbox? I can't wait to see more pics.

retrocarclub · 14-02-2008, 17:24

Quote:

Originally Posted by Jack

Awesome build! Are the engine mounts different on an XE to the standard engine?

And you've used a Manta gearbox? I can't wait to see more pics.

Yeah the old Cavalier engine mounts wouldn't bit but luckily I had some left over Manta ones that worked fine. Technically mk1 Cavaliers are the same as Mantas and Asconas underneath so lots of the parts are interchangeable, like the manual prop for example.

Yes it is a Manta gearbox. Luckily I know of an old mechanic that has a few rotting Mantas sitting around outside his workshop and he kindly sold me all the parts for next to nothing.

retrocarclub · 11-03-2008, 22:59

Time for an update.

Over the weekend I stripped out all the interior, cut off the top of the old auto box and re welded and seam sealed a manual one in its place, cleaned, de rusted and cavity protected the foot wells, removed most of the soundproofing, ran the wiring for the R1 fuel pump to the boot and finally refitted the carpets and interior.

I also collected a stock 2.0 Manta exhaust and my bike carb manifold. It was a bloody busy weekend - on Sunday I started at 9am and finished at 11.15pm! - but well, well worth it as I've now got gears.

My brilliant new inlet manifold:

And my 15" ATS wheels (courtesy of eBay.de), sporting 4 new Bridgestone 195/50/15 tyres (bargain of the month as I got all four tyres & fitting for £60!).

She's coming along nicely now

retrocarclub · 11-03-2008, 23:02

And tonight, I trial fitted my bike carbs..

Under-bonnet clearance is tight!

peester · 11-03-2008, 23:05

ooooh yes sir!

Vanweez · 12-03-2008, 11:31

Awsome looking ride dude, keep up the good work

DAVE TURBINE · 13-03-2008, 22:10

BRILLIANT!!