Work Has Begun!!!

[mike hayward]

After hard days work i got to start on the Cav, having never taken an Air model turbo apart before i encountered an unexpected surprise! the front engine mount my gosh its huge! well off now as is the Air con pump must have saved loadsa weight here!!!!!

Anyway's got the engine out had a look at where i am gonna have to start Plasma cutting out for intercooler its gonna be interesting!

some pics:

Before i begun:


Bye bye dormant pump!


That dreaded mount/bracket all in one ! its massive!


out you go!


Looks empty now ready for the steam cleaner tomorrow!


Friction plate or whats left of it! lmao

[mike hayward]

heres some intesting pics
Non air con cav front end behind bumper:


And mine!

[Jay w]

Geez... i would love a workshop that sized.....

Good work there....keep the pics coming

[wisecobandit]

Oh its a hard life when you have use of a plasma cutter...
Just think all us real men use 4&1/2" disc grinders and cold chisels and take so much longer


Besides which if i had the use of a plasma cutter i wouldnt get to go to A&E so often to visit the nurses

Never seen the front end of a cav looking like yours.Do all the air con models have twin fan fitments?Wander if the astra's with air con have a similar layout.

[mike hayward]

All cav's like that i belive bloody nightmare.

my work has let me do the car there, the workshop you see is my own workshop / nissan hut at the top of the yard i repair / overhaul plant machinery for a living in fact just in front of my car there is a small 3/4ton dumper with the rear axle carrier brackets snapped off which i have has to remove engine and hydrostatic pump to repair.

Plasma is only new to me at work up to then its been the 9" angle grinder and the trusty oxy acetalene torch RDS's favourite i might add!

[LEE69]

Nice going Mike

[Miles]

Cool, whats being done whilst its out?

[Tom Williams]

clutch is why its come out

[turbo matt]

nice one fella, not hanging round with this then

[Brett]

cool mike, whens it gonna be done?

[Trig]

Theres loads of meat left on that clutch yet ya bloody wuss lmao

[GSi-R]

Whats plasma cutting then? Sorry, but not heard of it before.

Those two large round circles at the front of your cav Mike look like a MK3 V6 Cav shell.

[mike hayward]

Continued....

continued progress today:

First i arrived in work and steamcleaned the engine bay



A moment t asses what needed to be done


after some spot weld drilling and cutting later

made up brackets to holf FMIC


The final result well almost the oil cooler is actuallt higher but almost like that


Fits like a glove and no cutting!


view through the slam panel


intercooler pipework



water spray nozzles and pum fitted



New Sachs clutch on


New injectors all fitted! fitted a new FSE regulator today also.


And final shot before calling it a day.



Plasma is using an arc of electricity to create a hot poit and then blowing through with compressed air to cut, makes life much easier.

And thanks RDS for your help today.

finish off tomorrow

[GSi-R]

Cool, great work

[chip]

Good stuff mike, that intercooler is what the factory should have done in the first place

[Heddleston]

you best come round mine when it's done mike- Can't wait to see it bud

[mike hayward]

All up and running now!

oh boy does go well

[Trig]

Whats the gen on the injectors chap?

[Heddleston]

All up and running now!

oh boy does go well

And i was out house hunting when mike called to take me for a spin

[Dave Hay]

*scottish member jumps in

thats ace m8 very nice work

[mike hayward]

Fueling is an issue at the moment trying to get to the bottom of it, may be to do with my reg.

mike

[Miles]

Whats the gen on the injectors chap?

http://www.racetronix.com/621031.html

Less than £100 delivered, might have changed with exchange rates.

[Trig]

Cheers Miles

Looks at website, looks at credit card, looks at website, headbutts desk....

[turbo matt]

fitted a new FSE regulator today also.

not my one i hope lmao only joking

looking good mate. so your happy with the results then?

[mike hayward]

nah mate had your mounts instead!!! to replaced thou

very pleased so far.