Donk's Corsa C Z20LET Build.

[corsadonk]

Well some highs and some lows today. I picked a nice used F28 clutch last night from Dale. Thank you.

I fitted it to the flywheel this morning, once I had that on it was time to get the gearbox on.

Next to the CDTI mounts.

Ready to go on, after a bit of sweating, it went on. I tried it with the engine at waist height this time, and it proved to work well much better than doing it closer to the floor.

Then I fitted the chassie mounts.


With the Astra mount I had to elongated the holes, it wasn't too bad because it's alloy.

Once I had the mounts in postion, I moved the engine and box into the bay. It went in really easy, miles more simple than a XE into a B anyway.

After that is was all doom and gloom. I tried to put the subframe on, but because I had fitted the front and rear mounts, it wouldn't go on so off they came. I got the subframe on but the bracket on the box above fowls it, so I had to drop it again, and cut it off.

Then I fitted the rear mount, which went ok a bit of messing about, and I had to go to the local agriculture supply place to get a few M12 bolts because I didn't have any that were long enough.

Then I moved on to the front mount, which just went downhill fast. I saved the brackets from the Astra, the 3 pot doesn't have a front mount. They seem to be as much use a inflatable pincushion. So after loads of farting about, I didn't get anywhere, and started playing with the clutch pipe, I didn't know the pipe coming from the gearbox needed a seal, so I clipped on the pipe, and removed the clamp letting fluid run into the bell housing. So I took it off again, check the box that came from the Corsa to see it had seal. So I'm waiting for it stop dripping, and I'll try again tomorrow.

Thanks for looking.

[Dale]

All fun and games Mike, keep at it

[corsadonk]

No it's not.

I can't do much today, stupid rain!

[dearing5]

yeah its not fun is it mate lol im still putting the engine back in my astra, conting box wont go on!!

good work on this though, always liked the c's!

[corsadonk]

I was surprised the gearbox went on really well, I've struggled alot in the past.

Cheers, I've a got bloke coming round tomorrow to come and make a bracket for the front mount, and weld them on. The clutch pipe is still leaking, so it looks like the lot has to come out again. So I make work out the problem.

[Craig-S]

I can't do much today, stupid rain!

Man up!

[GTE 16v]

The clutch pipe is still leaking,....

Trying to think of someone who knows stuff about fixing hoses.. nope can't think of anyone!

[corsadonk]

Man up!

Are you questionning my masculinity?

Trying to think of someone who knows stuff about fixing hoses.. nope can't think of anyone!

I know one, but he's got a week off work to play with a car. I've ordered a seal from Vauxhall which fingers crossed will fix it.

[Craig-S]

Are you questionning my masculinity?.

Nah i know you have both male and female qualitys in equal measures.

After all, who else goes to work in the morning, drifts their van around a quarry then spends the rest of the day in the back tidying up.

[JAYZCAVSRI]

Ive started out with a zlet project too but opposite ends!
Haha bought a C with a fooked engine and looking for a donor car now.
With regards to threading the oil ways and capping them what benefits that? Don't any metal filings fall through?
Cheers

[corsadonk]

I removed the main caps, and drilled out the hole with a pillar drill. Then cleaned everything, before refitting the parts.

Astra coupe's can be had for bargin prices, if Nemesis doesn't find it before you.

[JAYZCAVSRI]

Ah right sorry i thought you meant oil galleries for some reason Oops!
So does that help more oil to get in and lubricate the shells?
Im way up north so hopefully Nemisis can't be bothered going up to Scotland for a LET! Haha

[corsadonk]

The balancer shaft I removed has it's own feed from the main caps, you need to blank them off. So the oil stays with the crank.

[corsadonk]

I've stopped being a wimp and did some more work today.

Boxer from T.H.Whites came round on Thrusday and welded on and made a bracket for the front gearbox mount.

This is what I managed with my poo fab skills.

A picture of his van, but for some reason I didn't take a picture of what he did.

At some point I fitted the gear stick. I'm not gonna put the centre console back till it gets a good hoover out.


I've had a bit of trouble with the clutch pipe leaking, I went to a local scrap yard yesterday, and got another bleed nipple fitting, along with a new seal seems to have solved the leak. I blead the system last night, and checked it this morning and it was still bone dry.

Then I fitted the new turbo, easier said than done.

I helicoiled the bolt holes for the throttle body, and fitted the TB and top hat, as well as the LET loom, and a few other bits. That little lot took a few hours, and was getting bit too cold so called it a day.

I've got the subframe in the back of my van, which I'll was and give a little lick of paint when I get a minute at work.

[corsadonk]

This was how I left it.

[GTE 16v]

Top work Mr Donk, be great to see it running.

[Dale]

Coming together well mike keep at it...

[corsadonk]

Top work Mr Donk, be great to see it running.

Thanks Dave, bloody right it will be.

Coming together well mike keep at it...

I'm gonna see what can get done in the week after work, and fingers crossed the weather will be dry on the weekend.

[corsadonk]

I bolted on the subframe with new lower arms, today after work before it got dark.


My top hat on the throttle body is a tad high, so I'm gonna keep a eye on it, I might need to trim the inside of the bonnet, but it isn't too much of a problem because the bonnet shuts fine.

Then I did a little mock up for my exhaust to see what needs doing, it needs a bit chopping out and the o2 sensor boss moving.

How it will look at the back.

[Benn]

Looking great Mike. Helping me learn for if i do one...

[mk2astraturbo]

great work chap , you was brave working in the wet n cold today

[corsadonk]

Looking great Mike. Helping me learn for if i do one...

Get on it. It's easier to fit than the older stuff.

great work chap , you was brave working in the wet n cold today

It's just cold down here, I'm working in it all day so you almost get used to it.

[corsadonk]

Back to square one again, I had an hour or so today, so I took the engine and box back out. I've bought a new slave and clutch pipe, to try and get rid of the leak.

I'm gonna give it a good clean, and fit the new parts, if I get some time at work tomorrow. I'm off Wednesday so if it's dry out I'll get it back in, then hopefully back on it's wheels over the Easter weekend.

[corsadonk]

I had a bit of spare time today, so I thought I'd change the slave and pipe. When I moved the box so I could work on it I heard a rattle from inside.

It sounded like metal, so I took the selector off, shook it about a bit and this fell out.



Thinking to myself cool, that was lucky, I'm glad I took the box off. Then I bolted the selector back on, which didn't go very well.


When I tightened up the last bolt, I heard a load snap.
When I removed it I found a tad had snapped off, so now I need one of them. You can see the bit in the last picture to the right.

It really feels like this project is against me, and I'm pretty close to giving up.

[Craig-S]

It sounded like metal, so I took the selector off, shook it about a bit and this fell out.

.

That will teach you to lock your shed door at night