The Daily 5Door & C20LET project

[Danny w]

Hi Lads & Lasses some of you may know me from Corsasport but i've decided to sign up and becom a member here aswell due to starting a new Project along with the current daily corsa 5door. Hopefully a few of you would provide me with a bit of info through my next build lmao

This is the daily which i've ownded since passing my test in 2005, first car and one that has got me vauxhall mad, its a Corsa 1.4 8v LS
Its served me well and is near on 180k miles and still runs like a dream, been through a lot of changes with this car all work carried out by myself but is now starting to show her age with the dreaded rust & rot bubbling up over the paintwork and chassis legs

Current spec is flocked interior with cali leathers, irmscher kit (front bumper, lower spoiler, side skirts, rear bumper, roof spoiler) Coilover suspension, 2.0 brakes & BBS rm wheels loads of other subtle changes but if you want to read more into it my project thread for this from the start can be found here: Corsa Sport - for Vauxhall, Opel and Holden Corsa and Barina






So thats the Daily which is on going while i'm sourcing parts for the next project, being a C20LET 5 Door.

Danny

[Aberdeenloon]

Very nice car mate, And welcome to the land of vauxhall

[Benn]

Love the rims dude.

[Kev_G]

its something different the car so to me its full of win

[corsadonk]

I like this car, not many of us with a full pre97 front bumper

What are you doing, swapping over all the stuff from the older one?

[Collateral]

Yes 5 door corsa's FTW !!!

Nice too meet you mate, have alook at my thread i got a 5 door aswell

[UnLuckY ChuckyY]

Wahay another 5 door!

Im definetley going to keep my eye on your project and its looking amazing.

[Dale]

welcome Danny, keep us posted

[Collateral]

Thats the spoiler i want on mine

[UnLuckY ChuckyY]

Thats the spoiler i want on mine

Is that the one you provided the link for in your thread?

[Collateral]

Is that the one you provided the link for in your thread?

Think so lol ... either way they look roughly the same anyway

[m20nay]

tidy motor that pal... your next project should be good aswell!

[Danny w]

hey lads thanks for the kind comments & replies, been a bit busy over the past week with work so havent had much time to get on the internet but thought i'd nip on while i've a few minutes spare for a quick update.

corsadonk: hello mate yeah the pre97 stuff is pretty rare Eventually yep all the interior/exterior parts will be swapped over onto the new rebuilt shell.

collateral: thanks mate, i've just had a look through your project and i'm liking the progress so far

Thanks Dale & unlucky_chucky the rear spoiler is a Irmscher spoiler if thats what your after? there are several types out there with or without the high level brake light

m20nay: thank you, yeah hopefully it should be good. I've a lot planned for it but know its going to take some serious hours and £££ lmao

So heres a quick update on the daily 5door, I got my hand on a second irmscher front valance and decided i want a smooth front to suit the rest of the car When doing this sort of work your much better off having things plastic welded, its much much stronger, wont crack, shrink or peel off like layers of fiberglass or filler.

Plastic welded towing eye:



Then the number plate recess



light skim of filler



Primer



I managed to get round to fitting it the other night and took a couple of quick snaps, i do have the irmscher front lower spoiler aswell but due to a slight pothole related incident over the winter months i've had to do some repair work on it lmao still it shall be going on once i've re-painted it and will finish off the front end.








Thats the progress so far but i'll have another update for you either late tomorrow night or sometime sunday once i've picked up the C20LET engine

[Danny w]

Well as promised heres an update with the engine i shall be using, more to come once i get it up on the stand and start work on it

[Collateral]

Love it mate, thats what i love about the 5 door they look wider from the front than the 3

[Danny w]

As the engine is out and on a stand i thought it would be rude not to tart it up a tad so i set about prepping and de-greasing for paint.
So far i've got the block and head done but should have more progress and it built back up over the next week

[Danny w]

Thought i'd take some time to update this
Well heres a couple of quick pics of the engine after a bit of a tidy, up i've still more to buy and more painting to do but its getting there, cambelt cover & rocker cover will be going a mettallic grey once its in the car





And here's the new shell, Quite a clean example, GLS spec so has a few electrics etc.




Only issue was the head gasket had gone but thats not a problem as the LET will be going in it

[Danny w]

We got round to getting the chassis plates welded on and getting the engine bay strengthened and sealed.




all the little blemishes and rust we found have been treated & sealed. Heres a couple of pics of the engine bay painted up and ready for the new lump

[Danny w]

Time for a few updates today, Sorry for the lack of progress lads :P

Started off early afternoon by fitting the Lightweight flywheel and arp bolts, then getting the clutch kit on





I'll be running the 6 speed F28 gearbox on this car, 2 wheel drive conversion fitted and quaiffe diff helps things out, decided to go with a black gearbox to match up with the painted block




Finished the afternoon with the engine sitting nicely in the car






now the engine is sat in the car, i could really do with some help with the following:

Fuel lines, how have people sorted this? as the existing lines in the bay have the wrong size unions?

Speedo cable? use the original corsa one?

Vacume pipes on the inlet, need some help or advice (what goes where) same with the pipes running to the top left of the rocker?

brake servo, looks like i need to change the pipe for a flexi to run it round the inlet?


Any help and info is much appreciated
Danny

[dannyboi16v]

ive seen people cut the unions off a vectra ecotec, cut your ones off and join the veccy ones to the corsa ones with pipe joiners.

i think you can use the original speedo cable but dont quote me on that

the main vaccum come from the brake servo, on the right hand side on the inlet manifold there is a thread. screw the pipe from the servo onto this, the two pipes on the top left are breather pipes. the big one goes just below the throttle body on the inlet and the smaller one goes below on the inlet too

hope this helps a little

[Benn]

Yes use your speedo cable.

[Danny w]

Thanks Very much Danny

re:fuel lines, I'll source a few parts from the scrappy this week and see how i get on.
A few people have mentioned about using the existing corsa speedo cable (i'm running the f20 speedo ring on the f28 box) so i'll have a look at this now

Ah yes i see it now, perfect i'll get a bit of pipe to extend the servo vacume.

Benn, thanks for the diagram made it a lot clearer and easier to understand, and thanks for the post in my other topic

Danny

[corsadonk]

Looking good, I saw your smoothed bumper at Trax this year. I'm not sure if I'm gonna keep it for my new build.

[turbojolt]

nice cars mate brave choice choosing the 5 doors any reason for that and i love the wheels on your daily driver very nice

[Danny w]

Thanks for the comments guys, Reason i chose the 5 door was that i quite like the shape/lines of the car and i thought i'd stick with what i've got to re use a lot of body/interior parts.