Astra Edition 100 Re-Shell... Into a Van.

[elgan]

Story starts with a basic Envoy 1.7 DTi on a 2002, the engine gave up the ghost on me. It sat around a couple of months. When i had an idea, and shortly found a 2004 Edition 100 Coupe 1.8 Cat C write off.

I picked the Coupe up 3 weeks ago last friday, and the dismantling, scrapping, rebuilding and some painting, has all been done in those 3 weeks. Im very pleased with how quickly it came together.

The Edition 100 had covered 40 odd thousand miles, altho it didnt drive, it started and ran.

I worked to transfer every single part including wiring looms across.

It took about a week to get the coupe totally dismantled and weighed in.

I think the pre accident condition of the coupe was nigh on immaculate. Carpets, Leather, Surviving body work all in fantastic condition.

Juding by the car its driven square into some kind of post, which has then fallen onto the roof and the boot.

I removed everything from the coupe, engine, fuel tank, lines, ABS, brake lines, Air con, piping, all wiring looms, full interior, etc etc. For reference, it weighed 640 kilos as a pretty bare shell with just suspension and wheels fitted.

Once the coupe was stripped and gone, i virtually had to do the same to the van. Removed the blown 1.7 dti, full dash, looms, etc.

By doing this, the once basic van has now gained a few new features...
Electric Windows and Mirrors
CD Player and Steering Wheel Controls
Air Conditioning
Cruise Control
On Board Fuel Computer
Factory Fit Alarm
Illuminated Sun Visor
5 Stud Hubs, Rear Disks, and ABS
BBS Wheels
Heated Leather
Leather Steering Wheel, Silver Dash Trims, New Clocks
Reach and rake steering wheel
Coupe Bumper, skirts, headlamps
40k mile Engine and running gear.

From doing the reshell, all ive needed to source was:
Radiator and Air Con Radiator Pack
Cat Lambda Sensor
Coupe front bumper
Drivers Side Engine Mount

....everything else was there between both cars

Remaining to Source: (Inbox if u can help)
Electric Window Mechs and Mirrors (Coupe unsuitable)
Coupe Front Foglamps (Bulb holders broken in accident)
Wiper Linkage, van one is worn, forgot to remove from coupe
Pass Side front jacking cover
Air Bag ECU, these are scrap once airbags are deployed

So i now have an 'Edition 100' Van, with every single part from a 2004 40k mile coupe. It drives really well, quiet engine, all the gadgets work!

Couple of jobs remaining..
Fit OPC Rear Lamps
Join van rear loom into coupe interior loom
Traction Control Light on
Fit sourced parts listed above
Fuel guage does not work.. Cant remember if it worked in coupe or not, changed sender, no change

I built it with a view to bring it to billing, the van had remaning tax and mot, so providing I have a good week with the finishing touches it will be there

[scotty GSI]

looking forward to seeing this at billing

[elgan]

Ready to be dragged home to South Wales from Bristol..


Back home and on my drive awaiting its fate...


I didnt take many pictures while stripping it down, but i removed everything.

What was left loaded onto a trailer..



I used a 2 post ramp just to remove the rear beam and tank, engine and box..


Then last stop was the scrap heap

A picture of the heated cashmere tan leather, exclusive to the Edition 100 model..

[elgan]

As i got it, in all its glory.. but i had already swapped rear beam before taking a picture..


Basic Interior..


Addition of a Coupe front bumper, and the coupes front suspension legs and wheels..


Full interior out..


Wiring loom...


More behind dash..


Had to make new holes in the bulkhead to carry the air con piping..


Knackered old DTi...


New engine in and mounted..

[elgan]

First trip was for a wash down..


Back in the workshop with his brother sponge bob, trying to solve fuel guage probelm but to no avail.. help..


Colour Coded Back Bumper, Side strips, Boot handle and Mirror Case..


Done a job on the vans original headlamps as the coupe had snapped fixing points..


Before and After Flatting and polishing lamp lenses.. Amazing...

[elgan]

[rad_brad]

Wow that is awesome!

[Kev_G]

cracking work you have a thing for epic projects lmao

[gsigav]

been thinking about doing something like this with a estate as i now need a family car

[calibra-keith]

nice work, i like the yellow van is that the same van that had a crazy powered LET ?

[elgan]

thanks lads.

yeah thats the same yellow one.

all being well ill have them both at billing

[Benn]

Very cool, nice project. I'd say they hit a lamp post.

[Grant_nova]

love the van pal. i fancy one soon!!

[astrasaloon]

drop it 40 mm !

[vauxal]

I like that alot Elgan fair play .

[elgan]

Here are some 'For Sale' Pictures i used of the almost finished article

[elgan]

The van didnt sell. Even after removing the leather and fitting coupe turbo alloys and reducing the price.

Ive sold my C20LET Yellow mk4 Van and found some enthusiasm to do a few more bits and pieces to the white van.

Now to fit:
Prodrive front bumper
Lowering Springs
Tailgate Spoiler

I have the BBS wheels and Cashmere Leathers Listed for sale. Unsure whether to fit them to the white van or not yet.

Since the pictures ive also fitted colour coded door handles

[GaryVaux]

ha ha, its knowing when to stop, will look great lowered (i think you should keep the coupe bumper and bbs rims, just looks right!)

[Th0m45]

looks good mate! i was actually eyeing this one up on pistonheads a few weeks back!

[DrewyCoupe]

good work mate

[elgan]

picked up some lowering springs of some description last night. will get to work on that this coming week

[elgan]

ive got my lowering springs half fitted. more to come when my locking wheel bolt remover arrives for the fronts.

the prodrive bumper i have prepped and painted
the new foglights need some finishing and the silver screws removed.
but its ready to fit to the van (white coupe bumper for sale)

the silver bumper was heavily peppered with chips


primer


paint


new foglights, mesh replaced and new number plate

[Benn]

Get working on that nova.

[elgan]

picked up a LET ecu for him last night as it happens

[elgan]

2012 UPDATE

Ive got round to fitting the lowering springs, refurbishing the alloys in gloss black, fitting the SRi Turbo front bumper, and Painted the breaks to finish

Heres the van with the bumper newly fitted, and the rear lowering springs on


Typical kerbed SRi T alloys x4


Refinished in Gloss Black


Front Brakes Before


and after


And the final product


I will get the van cleaned and polished and the smoothed center caps fitted at some point this week. Delighted with how it now looks