MK2 Cavalier Project

[mikegray]

Hello all, I thought I would put up a thread for my Cavalier.

I have owned it for a few years now. I used it as my daily driver back in 2003/04. I then decided that it needed a proper rebuild. The car itself is a genuine SRI 130 but unfortuneatly it has had been abused and not looked after by previous owners. So I gave it a mass clean, polish etc and it made it look alot better even though it had horrid stickers, vents etc on it






Then I removed the 144,000 engine that was still good and put a redtop in its place. Along with a 35mm spax shock and spring kit.




After that I drove the car around for a while, and took it upon myself to take it of the road to sort out any rust, put some new bits on and get it resprayed. The paint job on the car is terrible it really is. So in the garage it went and it hasn't come out since

After recovering from Meningitous I have now found the love again. I'll give you the breif update from previous progress up until what I have done today.

Lots of stripping, welding and painting.





I can not find the pictures of the finished floor inside the car, and the rear of the floor, I will put some up tomorrow.

I decided to weld underneath aswell even though it was done inside. It was painted then with rust protector then black hammerite, and today I waxoiled the floor and chassis because I have just finsihed welding the rear chassis. Apologies for the pictures.






The offside rear chassis was no good so that got cut out and rebuilt it, to its original 2 skins thick. This has been over the past couple of weeks..









The rear chassis is done both sides all welded painted etc. Im waxoiling it tomorrow, inside and out. I would have done it tonight but I got told of for making lots of noise

So the current activity as follows, finish waxoiling the floor and chassis. Im getting another mk3 to cut out the wheel well to weld in. Im also going to use the rear beam as mine isnt great, along with the fuel lines. Brake pipes will be made, then I can bolt back in the rear beam when its painted and the fuel tank etc which I also have.

I have 5 stud Cav brakes to go on the back, it did have 4 stud discs. Vectra 308's on the front behind Cav T wheels.

I have stripped my gearbox to swap casings, I have to swap the diffs over then it can go back together. Reason being an F20 wont fit straight in and I have a spare F16 from a mk2 so I am just swapping internals

The engine bay hasn't had much done to it as I have been doing the rear end of the car and inside first. Its stripped ready apart from the servo/MC and steering rack.

Ill put up some pictures of the floor and wheel arches tomorrow when I take them along with tomorrows progress.

Thanks for looking and sorry for any headaches

[mikegray]

I had some progress today, but i'll start with the pics I said about in the other post. I couldn't get a good picture of the whole floor inside as its got alot of bits in there, so I took a couple of pic's to give you an idea. When the interior goes in hopefully next weekend, I'll take a few good pictures then.




I have almost finished the rear wheel arches, the inside half. the passenger side has been done just needs waxoiling. The drivers side has been done and also need waxoiling.



I thought I had taken a picture of the drivers side but I havent Will pop one on tomorrow.

This is the gearbox casing I will be using it is now stripped ready.



This is the F20 internals, the diff is still in the casing at the moment. Im hoping to swap them over tomorrow I have the gaskets and seals etc aswell. Im using the standard F20 for the time being, becuase I want to make sure im happy with the F20 ratios as I have never driven with one before. I also have an F28 to put in my mk3 so I will be able to compare the two.



I havent done a great deal to the front wheel arches yet because off making new engine mounts etc. There not in bad condition so not much work to do to them hopefully.

As for today, I mangaged to get to the point where I have finshed waxoiling the main floor, inside the chassis rails and on the outside. Which just leaves me the spare wheel well and the surrounding boot floor which isnt alot, and the rear wheel arches. So im happy with that. I'll put up some pics when its all dry. Also I removed the dreaded towbar which did give me a few problems... and lots of scotch locks later



Looking at that it doesnt look as bad I might clean it up out of curiousity.

Also I found lots of wiring in the boot that wasnt connected looks like an old alarm of some sort. Then I just spent the day sorting through which parts I need next.

Next weekend I will be getting the mk3 to break for bits. Then I can weld the spare wheel well and paint up the suspension components and put it back together. I ordered some rolls of copper brake pipe on friday so I can make up the front to rear as there's a joiner at the base of the bulkhead where it joins the floor.

When that's done I can focus on the engine/bay. I have a 74k X30XE to go in, using vectra management for the time being. I have all the manifolds, the sump and the rest of the bits I need. I will have to wire in the immobiliser as the mk2 doesnt have the immobiliser like the newer vauxhalls, so I can make a loom up. I also now how to do that

There is a manual steering rack on there at the moment but, I have a genuine reconditioned MK2 cav powersteering rack to go on. I do have the pipes and the pump but I wont be able to use them as the V6 is different, but i have the V6 pump just need to sort out some pipes which will be easy enough.

I have most of the parts I need its a case of putting them back on.

As for the exterior the car will be jet black. Its being taken back to bare metal and resprayed. Not by me The bodyshop at work will be doing it for me. I have a new front pannel complete, a drivers side rear quater complete, passenger side wheel arch repair section to go on. I probably will by new front wings and bonnet too. As for bumpers I have a full Calibre Kit thats new and unpainted. I will be having my main beam spotlights mounted in the calibre grill, hopefully the end result will be awesome. Thats what im aiming for

I dont think I have missed anything apologies if I have. More pictures and updates to come.

[vxlaney]

looking good mate, keep up the good work, i really like the mk2 cavaliers, got a 1985 1.8 sri in me barn. storing it up for now

[Galahad]

Much easier to cut out the horizontal section of a MK3 subframe with the rear gearbox mount position and just weld that onto the MK2 Subframe, less dicking about stripping boxes down, especially as the MK2 gearbox mount, I have no belief it will support lots of weight and any energetic starts too much.

[Dazzy130]

Good little project you have going there mate

Am in the process of spanking a black saloon up

[Stephen SRi]

wow think i am in love
mk2 sri 130 with redtop in love
keep up the good work mate

[dj_woodster]

is very nice to see a sri 130

[paulash]

nice car mate nice work love my mk2 its a sri 130 saloon with redtop am on wi tidying up at minute its in about a million peaces lol


keep it up mate there well worth it

[mikegray]

Originally Posted by Galahad

Much easier to cut out the horizontal section of a MK3 subframe with the rear gearbox mount position and just weld that onto the MK2 Subframe, less dicking about stripping boxes down, especially as the MK2 gearbox mount, I have no belief it will support lots of weight and any energetic starts too much.

Thanks chap im glad you said that, I have pondered about this. I done it this way to first as I will find it easier to get the engine mounted. As im not sure how the F20 will cope. I do have that section which I was tempted to weld in even if I didn't use it straight away. Thinking about it now I am concerned about the weight on the mounts.

Originally Posted by Dazzy130

Good little project you have going there mate

Am in the process of spanking a black saloon up

Top work chap

Thanks for the other comments guys.

I haven't achieved an awfull lot today. I have just done abit of welding to the boot floor in the corners. I havent taken any pictures at the moment. It needs grinding back that for sure I will get my two little repair pannels tomorrow so I will make a start on that.

[Brett]

Rear chassis legs grrrrr!! I had exactly the same on my old white SRi hatchback!!

Originally Posted by Galahad

Much easier to cut out the horizontal section of a MK3 subframe with the rear gearbox mount position and just weld that onto the MK2 Subframe, less dicking about stripping boxes down, especially as the MK2 gearbox mount, I have no belief it will support lots of weight and any energetic starts too much.

Now thats a ****ing great idea!! Theres me worrying how to fit an F20 without butchering the shell, and theres the answer!

[Greydj]

If you put the Mk3 rear mount in at least it will be there ready if you decide to change to the F28 to take the torque from the X30. There is a good chance that you will not like the low 5th of the F20 when you have all that the power in the light MK2 (consider using the the higher 5th from a F18, similar to 6th in the F28) as you will always be trying to change up another gear when you get to 2.5-3k revs in 5th.

How long has all this taken you?

[mikegray]

Originally Posted by Brett

Rear chassis legs grrrrr!! I had exactly the same on my old white SRi hatchback!!

Now thats a ****ing great idea!! Theres me worrying how to fit an F20 without butchering the shell, and theres the answer!

At least the spring seats are still available

[mikegray]

Originally Posted by Greydj

If you put the Mk3 rear mount in at least it will be there ready if you decide to change to the F28 to take the torque from the X30. There is a good chance that you will not like the low 5th of the F20 when you have all that the power in the light MK2 (consider using the the higher 5th from a F18, similar to 6th in the F28) as you will always be trying to change up another gear when you get to 2.5-3k revs in 5th.

How long has all this taken you?

Ah the f18 fith gear, good idea. I forgot about that. Is the 5th in the F20 quite pants?

As for time, alot The work itself not that long its just that after april the past 2/3 yrs the car hasn't been touched

[Brett]

Originally Posted by mikegray

At least the spring seats are still available

When we did mine, we dropped the beam down and the nipples that hold the spring in place fell of the beam, they were gone on the chassis leg!!

I was so lucky my mate had a spare beam lying in his yard!!

Wouldnt bother with the F18 5th gear, nowt wrong with F20 5th IMHO

[Greydj]

Originally Posted by mikegray

Ah the f18 fifth gear, good idea. I forgot about that. Is the 5th in the F20 quite pants?

Depends if you like relaxed, more economical cruising or not. With that engine you only need a 3 speed box

I think that my Mk3SRiXE with the F20 is undergeared but then I prefer the F16WR to the CR. To such an extent that back in 1983 when I replaced my A reg Mk2 cavalier SRi I had to change to a GLSI to stay with the WR box.

[mikegray]

Originally Posted by Brett

When we did mine, we dropped the beam down and the nipples that hold the spring in place fell of the beam, they were gone on the chassis leg!!

I was so lucky my mate had a spare beam lying in his yard!!

Wouldnt bother with the F18 5th gear, nowt wrong with F20 5th IMHO

Blimey, I dont think I have heard of them rusting off from the beam before. Mind you my beam is rusty thats why Im going to use a mk3... hopefully Ill double check mine see if it has or been done.

I did by a beam off you once brett from one off your GTE's I used it for my rear disc conversion.

[Chriscavturbo]

nice one, coming on well, i want to get mine out again this summer but i said that last year lol. keep up the good work

[mikegray]

Originally Posted by Greydj

Depends if you like relaxed, more economical cruising or not. With that engine you only need a 3 speed box

I think that my Mk3SRiXE with the F20 is undergeared but then I prefer the F16WR to the CR. To such an extent that back in 1983 when I replaced my A reg Mk2 cavalier SRi I had to change to a GLSI to stay with the WR box.

I did like the XE with the 130 box that was great, but that just revved to high at crusing speeds.

It would be nice to have a sort of crusing gear. Thats why im trying the F28 in my mk3 to get an idea of what its like, and also trying the X30XE with the F20 before I start buying LSD's etc.

[Galahad]

Originally Posted by mikegray

I did like the XE with the 130 box that was great, but that just revved to high at crusing speeds.

It would be nice to have a sort of crusing gear. Thats why im trying the F28 in my mk3 to get an idea of what its like, and also trying the X30XE with the F20 before I start buying LSD's etc.

X30XE with F20 will be rapid, but a handful, I suspect a MK2 Cavalier is lighter (just) than a MK3 Astra, and I had the X30XE and F20 in a MK3 Astra and once it traction, it was quick as hell!

[Brett]

Originally Posted by mikegray

Blimey, I dont think I have heard of them rusting off from the beam before. Mind you my beam is rusty thats why Im going to use a mk3... hopefully Ill double check mine see if it has or been done.

I did by a beam off you once brett from one off your GTE's I used it for my rear disc conversion.

I might have a pic on my other laptop of the remains of the beam.

Yeah that was my rear beam you bought, forgot all about that!!!

Ive got an F28 on an XE in my GTE at the moment, I kid you not its like the gear it always needed. Perfectly at home on an XE.

[mikegray]

Originally Posted by Galahad

X30XE with F20 will be rapid, but a handful, I suspect a MK2 Cavalier is lighter (just) than a MK3 Astra, and I had the X30XE and F20 in a MK3 Astra and once it traction, it was quick as hell!

That astra was cool I think it will be quite nice with the V6. My only real problem is the suspension. The Spax shocks and springs came as a kit. It gives me a 35mm drop and it handled realy well but the suspension is soooo hard. Theres virtually no give at all in the shock. You can sit on the corner and it wont move. So im abit concerned about damaging the shell through twisting etc. I might try some good quality standard shocks with the springs and see what its like.

[mikegray]

Originally Posted by Brett

I might have a pic on my other laptop of the remains of the beam.

Yeah that was my rear beam you bought, forgot all about that!!!

Ive got an F28 on an XE in my GTE at the moment, I kid you not its like the gear it always needed. Perfectly at home on an XE.

I had a look at my rear beam and it had been repaired before. It isnt quite coming out in the picture but it is dark. I'll put one up on the weekend. It would be interesting to see your picture.

Do you notice the extra weight of the box? Im going to put my F28 on my MK3 V6 in a couple of weeks as I still haven't driven/been in anything with one fitted. Does the XE deliver the power nicely through the F28? Im hoping the F28 will cope with the 2.5/3.0 quite well.

[mikegray]

Some more progress

Lately I have been strpping out my newly aquired donor mk3. Its a hatch though

I have taken off the rear axle it has/had ABS which will makes things slighly easier. I also removed the fuel tank, and the sound deadning from the footwells/bulkhead. I cut the spare wheel well out aswell, I was going to cut of the chassis legs to keep but they werent very clever tbh.

I have trial fitted the fuel tank in the car and it fits lovely with a bit off adjustment to the tank straps. So thats good news, I have wil be ordering a new one tuesday as I was going to use the one I took out but the seam doesnt look great.

I have just started to clean up the rear axle ready for painting. I have swapped the diff over into the mk2 casing and have almost finished reassembling it. The majority of the time this weekend was taken up by the spare wheel well which upset me abit tbh. Just there were slight deferences in a mk3 hatch compared to a mk2 saloon

Its done now though, just needs abit of grinding back ready to be filled. I was going to filler it smooth etc but im not very good at it so my colleage in the bodyshop will do it.

Tomorrow im hoping to finish cleaning the rear axle and get it painted, finish reassembling the gearbox and get that painted. Put some underseal on the new wheel well and the surrounding boot floor. After that im debating as to go to work and make the brake lines or start to swap the bits over for the engine.

Just a few pics im affraid until tomorrow.

[mikegray]

Some more progress made today. I put some seam sealer and underseal on the spare wheel well, im going to see how it is when its dry because I might give it another coat. I put the gearbox back together, and started to paint it. I cleaned up the rear beam. ARB and fixings, road springs, shock absorbers, fuel tank straps and painted them too.

I also had to have a bit of a tidy up as it was a mess. The sound deadning that I have has dried out now so, I can put the rear section back in but i'll leave the front until the engine bay is welded up. I didn't do the brake pipes today as im going to do the fuel tank first. So im pretty much ready to the put the suspension and brakes back on Hopefully my new petrol tank will arrive tomorrrow, it should do they had it in stock. Ill paint that fit it, then put the suspension etc back up that is the plan

Here's some pic's

[Dazzy130]

Looking good matey

I've decided to get rid of mine now