87' Carlton - Add V8 and US cop car styling

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Thread: 87' Carlton - Add V8 and US cop car styling

  1. #176
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    Re: 87' Carlton - Add V8 and US cop car styling

    Quote Originally Posted by Johnny A View Post
    That's probably about 25 hours work due to the lack of room in there
    oh, screw that then.
    just run it as-is, and see how she goes

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  3. #177
    Admin/show reporter Johnny A's Avatar
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    Re: 87' Carlton - Add V8 and US cop car styling

    So I got some work done this weekend!

    I needed a towing solution for the front end, my original idea was an extra hole at the bottom of the O/S lower nudge bar bracket for attaching towing bar/rope etc... but I found this was annoying to work with and twisted when towed. On my old Lotus Carlton replica I modified an Astra-G setup and it worked really well so I went with that again.

    Front O/S chassis rail from Astra-G sourced:


    After much hacking:


    I refitted the bumper and used the towing eye as a guide to line up the threaded block:


    With some extra bendy yoga positions I was able to get the welding torch in the gap for a spot:


    Then blasted it on:


    Like a glove!


    I also started to build the nudge bar upper brackets but didn't take any pictures, will finish that off next weekend.
    Vauxhall Nova Estate - Isuzu diesel, EPAS and it's an estate yo!
    Vauxhall Carlton V8 - Lexus 4.0 V8, US Cop car paint and light bar
    I used to be a real jerk but now i'm a people guy

  4. #178
    MIG Regions Admin / South Central Regional Coordinator Benn's Avatar
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    Re: 87' Carlton - Add V8 and US cop car styling

    That'a very good idea! Might look at that for the rear of mine.

    I dare any of you to tell me you wouldn't let this upstanding young citizen slob on your knob like corn on the cob.

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  6. #179
    Admin/show reporter Johnny A's Avatar
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    Re: 87' Carlton - Add V8 and US cop car styling

    Small update:
    Although it might seem like i've abandoned this due to the lack of updates I have just been busy with other things, as a lot of you guys will confirm when you're good with cars you tend to supply and maintain all your family's cars which can be quite draining.

    In addition to this I have been selling off things to free up some much needed space and cash, Darcy approached me about purchasing my failed Nova project which ended up with him purchasing it and me having a big void of room at the rear of the unit:


    Originally I was just going to tidy what was left up but I realised that the way I work is very inefficient as I just sit on the floor to do jobs and my tools are always scattered all over the place, so I grabbed some old wheel/tyres and some free laminate kitchen worktops and started making work benches:


    Added my tool boxes, found as many self-tapping screws as I can and started hanging things up:


    This was the last picture I took but since this i've added 2x 50W (300W equivalent halogen) LED floodlamps, 80 storage bins on two wall mounted panels, removed everything, tidied and either sold or thrown away a lot of stuff. The transformation is pretty dramatic and anyone who has visited the unit since thinks I must be ill!

    The Carlton didn't go completely untouched, I have been working the upper nudge bar supports but this is a long process to get them lined up perfectly with the holes in the front bumper. Pics to follow.


    Notice the long suffering Nova in the background, poor thing really needs some love... and a new engine!

    Vauxhall Nova Estate - Isuzu diesel, EPAS and it's an estate yo!
    Vauxhall Carlton V8 - Lexus 4.0 V8, US Cop car paint and light bar
    I used to be a real jerk but now i'm a people guy

  7. #180
    North Western Regional Coordinator Kev_G's Avatar
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    Re: 87' Carlton - Add V8 and US cop car styling

    Hasnt darcy sold the loon on now to
    Ein Projekt, das ist eine nie endende Entwicklung
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  8. #181
    Admin/show reporter Johnny A's Avatar
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    Re: 87' Carlton - Add V8 and US cop car styling

    Quote Originally Posted by Kev_G View Post
    Hasnt darcy sold the loon on now to
    Yeah, he said that a dream car came up out of the blue so he had to shift it on. I do know he gets screamed at when he brings another car home so it makes sense he would have to get rid if something better came up.
    Vauxhall Nova Estate - Isuzu diesel, EPAS and it's an estate yo!
    Vauxhall Carlton V8 - Lexus 4.0 V8, US Cop car paint and light bar
    I used to be a real jerk but now i'm a people guy

  9. #182
    Eastern Regional Coordinator Spinbitch's Avatar
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    Re: 87' Carlton - Add V8 and US cop car styling

    I want a Nova estate daily

    Welcome to MIG Performance Vauxhalls please follow the rules and enjoy our site or don't follow the rules and don't use the site :)

  10. #183
    Eastern Regional Coordinator Spinbitch's Avatar
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    Re: 87' Carlton - Add V8 and US cop car styling

    Or a chevette come to think of it

    Welcome to MIG Performance Vauxhalls please follow the rules and enjoy our site or don't follow the rules and don't use the site :)

  11. #184
    North Western Regional Coordinator Kev_G's Avatar
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    Re: 87' Carlton - Add V8 and US cop car styling

    Quote Originally Posted by Johnny A View Post
    Yeah, he said that a dream car came up out of the blue so he had to shift it on. I do know he gets screamed at when he brings another car home so it makes sense he would have to get rid if something better came up.
    no doubt that dream car will be bought and sold within a few weeks to knowing him
    Ein Projekt, das ist eine nie endende Entwicklung
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    WIP - Mk3 Astra More Door

  12. #185
    MIG Regions Admin / South Central Regional Coordinator Benn's Avatar
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    Re: 87' Carlton - Add V8 and US cop car styling

    Would of loved the rwd nova.

    I dare any of you to tell me you wouldn't let this upstanding young citizen slob on your knob like corn on the cob.

  13. #186
    Admin/show reporter Johnny A's Avatar
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    Re: 87' Carlton - Add V8 and US cop car styling

    Quote Originally Posted by Kev_G View Post
    no doubt that dream car will be bought and sold within a few weeks to knowing him
    Yeah no doubt!
    Vauxhall Nova Estate - Isuzu diesel, EPAS and it's an estate yo!
    Vauxhall Carlton V8 - Lexus 4.0 V8, US Cop car paint and light bar
    I used to be a real jerk but now i'm a people guy

  14. #187
    Admin/show reporter Johnny A's Avatar
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    Re: 87' Carlton - Add V8 and US cop car styling

    Update:
    Unit is looking a lot better:



    I wasn't happy with the cooling pipes in the bay, more so the rear ones for the heater matrix/LPG condenser so I decided to rip it all out and start again:



    Small pipe from rear coolant bridge to ICV joiner was originally rubber and run quite high so I made a metal one that runs a lot lower:


    Return from heater matrix to engine:


    All three new pipes:


    I started routing the LPG fuel feed too, it runs exactly like the fuel lines but on the other side:



    underneath using factory lugs originally meant for a carbon canister breather:


    I wanted to inspect the condition of the cambelt, I suspected it hadn't been touched in a long time as Lexus specify 90k!!! between changes. There are many different plastic panels intermixed with metal ones (mainly for the aux belt idler and tensioner), getting the bottom pulley off required a puller made from a modified rear caliper rewind kit:



    The idler pulley gets lopped off because im sick of people telling me its the drive for the water pump:


    Dismantled tensioner:


    Looks a bit used:


    Both idlers look very used:


    Belt has two teeth with signs of fraying:


    New Gates cambelt kit ordered!

    Picked this amp up off Tintin, should do well to power the two PA speakers:

    It accepts speaker inputs which is ideal:


    Got one of these going on the boot:
    Vauxhall Nova Estate - Isuzu diesel, EPAS and it's an estate yo!
    Vauxhall Carlton V8 - Lexus 4.0 V8, US Cop car paint and light bar
    I used to be a real jerk but now i'm a people guy

  15. #188
    Admin/show reporter Johnny A's Avatar
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    Re: 87' Carlton - Add V8 and US cop car styling

    Update:
    Had a lot of fun sourcing the correct timing belt. As fun would have it my engine is right on the border of being the later VVTi type, so the seller (whom I emailed with my donor reg to confirm part) sent me the VVTi belt kit! Of course you kinda have to fit the kit to find out it's wrong, the tensioner and idler were the same so fitted fine, the belt is 2 teeth longer than the correct one. The seller said they would only partially refund me because I fitted the kit! WTF I check it was correct with you guys! Anyways I did some digging and for some reason Gates do a kit for the VVTi engine but NOT the pre-VVTi, they do the correct belt separately but not as a kit.. even though the idler and tensioner are the same.

    I found the correct belt and ordered it, cost me 30. The later belt costs 45 so I messaged the seller saying if I send the incorrect belt from the kit back, will they give me 30. They said no so I just left bad feedback lol




    Handy 'cambelt installation for dummies' markers on the belt were a nice touch:


    As I put all the covers back on I sealed up and painted the old aux belt idler/fan and tensioner mounts:



    Next job was to finish off the front end, this meant finishing the welding and painting everything. The nudge bar mounts were checked with the bumper on, the top mounts are ever so slightly proud of the bumper face:



    Wings off again, hopefully for the last time:


    Paint removed from slam panel:


    Seeing as LPG burns hotter than petrol a cold air intake is more important than ever, so I cut a hole in the inner wing and sourced an 80mm stainless pipe to weld in. Any guesses as to what this pipe was originally for?


    Cut down and welded in:



    Front end in primer:


    The bottom section is just black:


    Slam panel and top area in white:


    I also modified the Senator headlights to replace the long range driving lamps with the indicators (adding silvertec bulbs), no pics but you don't see the work anyway.
    Vauxhall Nova Estate - Isuzu diesel, EPAS and it's an estate yo!
    Vauxhall Carlton V8 - Lexus 4.0 V8, US Cop car paint and light bar
    I used to be a real jerk but now i'm a people guy

  16. #189
    Moderator / Memberships Astra Dan's Avatar
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    Re: 87' Carlton - Add V8 and US cop car styling

    Stunning work there Johnny!
    They're there, in their room.

  17. #190
    Administrator. GTE 16v's Avatar
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    Re: 87' Carlton - Add V8 and US cop car styling

    Nice one Johnny. Looking forward to seeing it soon.

  18. #191
    Admin/show reporter Johnny A's Avatar
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    Re: 87' Carlton - Add V8 and US cop car styling

    Update: Got a little more done this weekend, first off if any of you have owned one of these engines in a LS400 you know the cold idle is stupidly high... like 1400rpm high! In the LS400 with its stock exhaust this isn't an issue as it's super quiet.. but when your system has a couple of pathetic straight through boxes its quite annoying. So from the local plumbing store:


    Add in the ICV line:

    Then simply turn until desired idle is reached! I settled on 1000rpm for cold idle as any lower and the engine doesn't like starting.

    A small tweak to the negative battery terminal - a modified MK5 Astra block:


    I finished off the air intake system too, the AMM is designed to have an 80mm pipe on the outlet and it bolted directly to the airbox on the inlet which is no good to me. So I took an 80mm aluminium pipe and sealed it to the intake side:


    HKS mushroom air filter:




    all done!



    Front wings have their Dinitrol put on:


    One thing that really annoys me about this generation of Vauxhall is the way the side repeaters are installed/removed when you want to remove the wing, I have always hated the idea of having to feed the wires through two panels. So to fix the issue:


    I installed all the cooling system and filled with plain water to see if the revisions have fixed the issues, check for general leaks and also make sure the fan switches on automatically:


    I'm happy to say it all works fine!
    Vauxhall Nova Estate - Isuzu diesel, EPAS and it's an estate yo!
    Vauxhall Carlton V8 - Lexus 4.0 V8, US Cop car paint and light bar
    I used to be a real jerk but now i'm a people guy

  19. #192
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    Re: 87' Carlton - Add V8 and US cop car styling

    Uh, that filter is a notorious POS, surely you have room for something better?
    Anyway, looks like you'll be driving it by the end of your summer
    NOTE, these are my thoughts and opinions, sometimes I'm wrong ;-)

  20. #193
    Admin/show reporter Johnny A's Avatar
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    Re: 87' Carlton - Add V8 and US cop car styling

    Quote Originally Posted by Gordo View Post
    Uh, that filter is a notorious POS, surely you have room for something better?
    Anyway, looks like you'll be driving it by the end of your summer
    Its what I had lying around from an old build, better than nothing for now. There is buckets of room for something better when I have some spare cash.
    Vauxhall Nova Estate - Isuzu diesel, EPAS and it's an estate yo!
    Vauxhall Carlton V8 - Lexus 4.0 V8, US Cop car paint and light bar
    I used to be a real jerk but now i'm a people guy

  21. #194
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    Re: 87' Carlton - Add V8 and US cop car styling


    At least it stops the mice and other crap getting into the engine in the meantime.
    NOTE, these are my thoughts and opinions, sometimes I'm wrong ;-)

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