Something a little Different....

[Dale!]

Had more time on him recently..

Got some more fuel bits through

Then I shot blasted the removable front panel

All primed up

Primed the front panel

Inlet runners primed

All painted

Connect under inlet for vacuum lines, air temp sensor and vacuum for servo

Inside inlet

New adapter for fuel rail need to machine down the new ones slightly

Next to mount the fuel pressure sensor and oil pressure sensor (Left fuel & Right Oil)

Route from regulator

Next was to modify the top of the tank, I epically ****ed my first one my trying to use weld on boss's....

So plan "B"

New part

Remove the connections

-6 through body connection with dowty washer top and bottom

Barbed connections for hoses inside tank

Fuel system mock finished

Then remove it all and fit carpet and cut away

Thats all for now

 

[ather`s]

fantastic!! going to be mental when its finished. love it

 

[Dale!]

fantastic!! going to be mental when its finished. love it

Cheers, yer should be fun!!!

 

[Dale!]

Got few more bits through

New exhaust manifold gasket and turbo to manifold gasket (Proper one to use as Vaux no longer sell this gasket....)

Got parts delivered from Owen developments. Turbo heat jacket, Worth a go as I want to get the Manifold Zircotec coated but I just don't have time before PVS I want it running early May in case teething problems..

Tial Q50 blow off valve in silver to match the external waste gate

Then I fitted the manifold and turbo with new nuts and fitted the turbo jacket

Cheeky shot inlet fitted now its sprayed

#

Got my custom Magnecor lead back for cylinder 1 which I had made at 64cm in length and the standard item is 54cm. Ignore the lead location its just for the mock up...

 

[Dale!]

Update time again...

Since reading Nic Barnes issues with mocal oil cooler sandwich plate, I have since taken it back and will run standard plate for now, If I suffer with high oil temps I will change for billet plate with remote stat and go from there like most things its trial and error

Rude not to put it through the parts washer

New filter as always

All fitted

Few bits to finish fuel system off

Inside

and underneath

Now was to sort oil return from turbo, fenny used rubber hose which IMO wasn't for me! I had some spare fluro silicone hose so i adapted that....

Old vs new

Measuring up

Then heat wrapped and used aluminum heat wrap tape to finish it off. I will also do coolant pipe the last thing I want is a thermal event

Heat wrap matting

Also did the breather to be safe

Location for EGT and wide band (Not fitted correctly yet.) I have a spare boss now as I will no longer be using a separate wideband as its built in the motec

Rebuilding

Next onto air filter location.....

Either normal place

Or looped around down the inner wing

Picked up couple for sensors (Air temp, post rad temp and Map sensor) Also machined the rail adapters and oil pressure to block adapter

Where i'm currently upto

 

[Berg]

Awesome as always!

Videos definately needed once its done

 

[cupra.al]

this thing looks like it could be a bit of an animal and it looks amazingly clean i dont even think vauxhall make them that clean.
i never thought that intake pipe would be man enough to go on the turbo clearly im wrong.
nice build though buddy been following this thread distantly.

 

[joshy514]

Soo much work on a corsa... i bet its worth it when your driving it though!? i cant believe how clean it is either!! you have done a fine job there. I'll have to give you a shout if i'm near swindon as i only live in gloucester, and occasionally drive through for work, would love to see it in person!

 

[Dale!]

Awesome as always!

Videos definately needed once its done

Cheers, I have videos from other stages of the build which are here:

http://www.youtube.com/user/DSDevelopments1?feature=mhee

this thing looks like it could be a bit of an animal and it looks amazingly clean i dont even think vauxhall make them that clean.
i never thought that intake pipe would be man enough to go on the turbo clearly im wrong.
nice build though buddy been following this thread distantly.

Cheers, I hope so but this year will be the lower spec version as I'm yet to get head done! Yer its reinforced by wire. Guy I know has one on his and runs 585 @ 1.9 bar on a GT35...

Soo much work on a corsa... i bet its worth it when your driving it though!? i cant believe how clean it is either!! you have done a fine job there. I'll have to give you a shout if i'm near swindon as i only live in gloucester, and occasionally drive through for work, would love to see it in person!

There has been alot of work and fun to say the least has been a total of 3 years now from standard to this stage and I do enjoy using it..... Yer sure be good to meet new people as seen in the thread it will be down Badger 5 for another power run as its a good comparison as its been RR'd there since day 1 and done god knows how many hours there!!

 

[GTi T]

Awesome as usual Dale, how's Robbie doing with his?

Tom

 

[Dale!]

Awesome as usual Dale, how's Robbie doing with his?

Tom

Cheers Tom. Currently at Bill's having AEM water meth and mapping although I believe turbo may be getting old when I spoke to Bill last Think the plan is to pick it up this weekend

 

[GTi T]

Sounds like a good excuse to me to have one of Bill's new Hybrids or a big turbo fitted,what ya reckon ?

 

[Dale!]

Think the plan is to go 2868 one Owens new hybrids iirc!!

 

[GTi T]

Sounds good!Anyway enough spamming your thread....look forward to seeing results from yours at Bill's soon mate

 

[ben450]

Excellent work as always mate I have so gotta get me some braided lines and anodized connectors I know they are not cheap but they sure look pretty

 

[Dale!]

Had a little more time this evening...

Sorted out my coolant feed and return and heat wrapped like the oil return

Also did my turbo outlet joiner to boost pipe as this is close to the downpipe

All fitted

 

[Dale!]

Been busy again first off was to design a sump plug to take new oil pressure temp sensor, as the temp sensor uses M12x1.5 trying to find adapter to M14x1.5 (sump plug) was hard enough and one that had enough "meat" to drill and tap a thread was impossible! So popped to Steve's (GWR Motorsport) and we designed this....

Adapters next to standard sump plug

Together

Also bought post radiator temp sensor housing to help monitoring....

Next I got to work with the Motec CDL3 dash, I want it to look as standard as possible, so it was time to start cutting and grinding, this is only a mock...

Rough placement with all standard dials removed and lugs

Done some more work to mount the shift lights but no pictures will update with more progress on dash soon

Mounted battery box

 

[Dale!]

Been doing a few more bits over the weekend

Carried on this the dash, heres whats left on inside

Trial fitting with shift lights/warning lights

Got my bracket back from powder coating

Started to rebuild and cut light panel to allow room for coolant hose

Also shortened by vac hose for master cylinder

On the rebuild

Got my intercooler pipes "bead rolled"

All on and mock fitting Tial BOF

Then got these made, rose jointed lower arms and track control arms (note the TCA are placed the wrong way around here)

Lower arm

All fitted, I have kept from spacer plates as it gives me clearance from intercooler piping. Lower ball joint spaces don't fit but this isn't an issue as the lower arms clear with F28 fitted due to different pick up points. The chassis was drilled for 1/2" bolts for lower arm which was fun with engine in. In the end I removed the engine mount and lifted either side to make sure the chassis was drill straight! Over all very happy with the kit and quality of welds!

Fitted post radiator coolant temp sensor

Fitted air temp sensor in the oil cooler housing

Getting there slowely

Coil fitted with leads

All for now

 

[Chambers_CUPRA]

Looks awesome

I wish my corsa let made it this far

 

[Dale!]

Looks awesome

I wish my corsa let made it this far

Cheers, Yer not many get to this level or have the "whole" package like this IMO

Little update nothing great....

Got some new shorter lower arm to ball joint bolts as I had spacers before

Had alittle play with adjustment of caster....

Wheel and wing placed on

Then got my new Big block hub flanges (Not conversion hubs) and knuckles back...

Knuckles with part grinded off for clearance for Alcon brakes

These will be powder coated now

Then I carried on with Dash mock...

Feel Wet lay carbon 1mm thick (Not crapped "carbon wrap")

Cut out to go into housing

Cut out for dash

Front face on with the motec shift lights/warning lights at top can only just see