Mk1 Cavalier

Could create a filter airbox arrangement as they should be (may be ) high-pressure at the base of the windscreen?

We got the prop measured up tonight. Cut the Vauxhall prop and the MX-5 prop down so we could attach both ends with them sleeved over each other, and when everything was in place we took the measurement.



Looks weird but the adjustable spanner was the perfect size to hold the prop perfectly level so we didn't have to hold it by hand. It clears the handbrake cable perfectly, and the handbrake recess for the handle unit isn't in the way either. Good news, looks like it'll be nice and simple to fit.

Going to send it off to a prop company local to me, my mate has used them before and says they're good, a proper old school setup with an old guy in a workshop doing the work. We'll get it sent off next week hopefully.


When this was done I took the exhaust system off again and got to work on raising the midpipe. I cut the lower part of the downpipe section of the manifold off, shortened it by about an inch and angled it a bit differently. This has both raised the front of the exhaust up to chassis rail level, and moved everything away from the fuel line a fair bit.

A mate at the unit gave me a length of brand new exhaust pipe he had been given, it was ideal for what I needed. I cut it down and got it welded onto my flexi pipe.



It's very simple and straight, I just had to weld a slight bend on the end after this so it would sleeve into the centre silencer. The angle is just a little bit off, and I got very frustrated laying under the car trying to sleeve it in. I'll get back on it on Saturday, just a small adjustment needed.

It looks far better than what I had before. This was just what I put together temporarily, but it was really quite bad, especially seeing as the manifold and rear section are quite nice.



Will start it up when it's on and see if it sounds any different.

Not much at all mate, the list is down to 15 items now to get it roadworthy, half of those are just little things that won't take long.

Haha, the joys of highlight posts that show the work done, doesn't show the many swear words in between, should have seen me last night when my midpipe sleeve just about wouldn't fit. Absolutely raging, cut my knuckle punching the underside of the car in anger 😂 It's been a ton of work, but yeah it's not actually been that horrendous overall. I wouldn't want to do it all again mind you haha.

Got a couple of bits sorted this evening. I can't have a car without music so got some speakers sorted I had lying around in storage. Just a couple of cheap Pioneer ones.

Sadly one of the only things missing when I got the car was the plastic cover from the passenger footwell, which is a shame. There really wasn't much room anywhere for speakers as the doors don't have room, the original setup just had a single speaker in top centre of the dash.

I got the speaker mounted down in the recess in front of the door. I'll get some better fitting carpet to hide everything, but this will work for now.



The driver's side was much better as I have the plastic cover for that area, so I got a hole cut out if it and mounted the speaker in it.



Feels pretty sturdy and is far enough away from the throttle pedal to not be an issue at all. The wiring for both sides is all done and I've tested them and both speakers work. Good enough for me, I'll just get a little magnet phone mount somewhere, will be nice to be able to use my Spotify when driving this.

Also found my coilpack bolts, so got those fitted. Checked the diff and it hasn't leaked a drop, which is good. We'll see how it is when it gets some movement in it.

Contacted JW Engineering up in Bexleyheath and they said they can do the prop for me, so I'll get it up to them some time this week.

So, big update. Got a load of stuff done!


Firstly, went in my box of random brackets and found something suitable to secure the fusebox into the bay:




Then Friday morning I took the day off work, borrowed my girlfriend's car and made my way up to JW Engineering in Bexleyheath to get the prop made. I always get a bit anxious going to a new place, not knowing for sure that they'll be sound. But they were class, the place felt old school, everyone there was super friendly, as soon as I arrived they were talking to me, asking my specs etc. I asked for lead time and he realised I was angling to have it done while you wait. He told the 2 lads in the workshop to drop everything they were doing and get it sorted for me, and for me to come back in an hour and a half.

Under an hour and a half later he called me, done. My UJs I provided had been cleaned up, prepped, prop made to size, welded, balanced, painted and even dried. Amazing. The young lad working there even brought it out to my car for me. Can't recommend them enough. Cost me £200, which is a good price for the work and the stupidly fast turnaround time.

Here it is:



Went to the unit and got it fitted. Perfect fit, measurements were spot on, and it went on easily.



Small amount of yoke sticks out of the box, the same as it sits on the MX-5s.



Rear end slotted on perfectly, I bought brand new U bolts and locking tabs set a while ago, always nice fitting new parts with brand new hardware. Prop clears everything fine, it's spot on.


With this ticked off the list it was a case of finishing off the other bits to get it driveable. We had started bleeding the brakes the other night, but ran into some leak issues and it got late. So I sorted the leaking rear brake line, re-flared a new one, turns out it needed to be a double flare on the end that threads into the axle flexible rubber hose, I had done it previously as a single flare, hence it leaked like mad. Much better now. A mate helped me bleed the brakes, and the clutch. Both sorted now and seem to be fine.



Nice clean fluid in the entire system is always nice to see.


Finally got my other steering rack boot fitted, the original one on this side was torn as well:



Much better.


A mate brought me an MX-5 steering hub, these fit the Vauxhall column perfectly. Original wheel is just too big, it practically touches my thighs, these seats really do not go back very far, and they're too high as well! I'll need to get some other rails and seats sorted in the next couple of months. Anyway there was a very slightly dodgy thread right at the start of the Vauxhall column, so my mate did a bit of filing work and we found a new undamaged nyloc nut. Sorted. All fitted, and this wheel will do for now. It's nothing special, but it works and doesn't hit my legs, good enough for me.



A nice retro wooden OBA would be perfect I think, might have to get one.

Also got the gearbox oil filled, no leaks, all good. With the stuff underneath basically all done, I cleared all of my stuff out from under the car, got the wheels back on, and dropped it back on the floor.



Looking good.


Went down to the unit again yesterday morning. Needed to get a few things checked, adjust the toe a bit to get it sensible and straight enough to test drive, torqued the wheel nuts up, cleared stuff out of the bay, tied up some wiring so it couldn't snag when the engine was running. Basically just checked over a load of stuff, made sure track rod ends were done up nice and tight after adjusting, looked over the brake unions and stuff.

Sat there for a bit with a few mates going "Is it ready?" constantly haha. Chucked another jerry can full into the tank. Over 5 months of constant work and late nights all came down to this haha. So I started it up and just went for it.



It drives! Clutch all good, nothing sounded horrendous, brakes a bit fresh and need some bedding but pedal works. Couldn't drive it far as needed to bleed the coolant, so we got that sorted, thermostat opened, fan came on when it should, nothing leaked, heater is lovely and hot, absolutely mint! Temp gauge works, but much like the fuel gauge the resistance is wrong. Dead in the red on the gauge is up to temp now haha. If it goes above the red mark we know it's gone bad.

Out in the daylight:





Cool seeing it outside, even if it is still filthy (I'll wash it soon!).


Once it was bled we took it for a test drive. All went well, I think the brake shield is occasionally just touching the front nearside disc, but other than that no dodgy noises at all under acceleration, braking, or steering. Prop is doing it's job, and the diff doesn't make any unwanted noises. We haven't really got it up to much speed yet, this is just the private road on our estate, did a little drive by video:



Sounds pretty raspy, I quite like it. It's pretty quiet when you don't boot it, and on idle it's not bad at all.


It's great moving it around and getting to see it from different angles:





We drove it around 4 up, and the wheels don't rub at all, even under hard acceleration. Suspension is fairly soft, but feels quite nice actually.


Got a couple of little issues to sort, exhaust definitely needs raising more, it is too low, I'll need to redo my midpipe and shorten the downpipe more, I want to raise it probably another 2 inches. General ground clearance will be absolutely fine, the sump is all just above the subframe so not worried about that. But the exhaust downpipe and midpipe will hit on speed bumps and I don't want that, my MX-5 is like that which is fine, but I don't want both my cars to be a ballache. Speedo isn't working, so I need to check that, and the right rear brake drum is a bit tight, so I'll have a look at that too, it is adjusted all the way out already, but it's all new, so I'll pop the drum off and see what I can do. Handbrake needs adjusting as currently only has 3 clicks in it, and needs slackening off a little. Other than that the steering wheel has a little play, so I think the column bearing needs doing, the hub and wheel itself are not the issue, both are tight and absolutely fine. It's fine to drive, but I'd like to sort it for peace of mind.


So so happy though, it just works. I can't believe it haha, you spend so long seeing it as a thing you work on, and fix things on, actually driving it for real is such a nice feeling. Starts on the button, seems to drive ok, very pleased overall. Once the few teething issues are out of the way it should be great!

4 hours sleep the last 2 nights so I'm going to bed after writing this, I'm done in haha.

Awesome

Can't wait to see this rear canoe-out in a private car park lol

That's a good point actually, thanks! I'll get it adjusted and see what it's like.

Haha, it'll be getting a fantastic 1 wheel peel burnout very soon.

Yeah great guys, always nice to deal with people like that.

Yeah it is cool, I still want a front lip though. The lights do stick right out like square boggly eyes haha, but I actually really like it, though it does look a little odd.