Vauxhall Cavalier GSI RestoMod Track Car
Discussion
Tyres fitted, and rears installed on the car properly.
I went with Continental PremiumContact 6 tyres. I obsessed over tyre choice endlessly, and in the end watched some fantastic tests on youtube on a channel called tyrereviews. While most of the big manufacturers have stopped making sporty tyres in 17'' these come out on top - albeit subjectively - as the best dry handling tyres for road use.
I was tempted by some out and out track tyres, R888's or similar but I won't be out on track for a while, at least.
I went with Continental PremiumContact 6 tyres. I obsessed over tyre choice endlessly, and in the end watched some fantastic tests on youtube on a channel called tyrereviews. While most of the big manufacturers have stopped making sporty tyres in 17'' these come out on top - albeit subjectively - as the best dry handling tyres for road use.
I was tempted by some out and out track tyres, R888's or similar but I won't be out on track for a while, at least.
Next up, the problematic sunroof hole.
Many, many moons ago the sunroof cassette was ditched in the name of weight saving. It amounted to several kilos from high up in the car.
The right way to 'delete' the hole would be to get a roof skin from a non-sunroof Cav. This has not been possible, it seems that on even the most basic models most people opted for a manual sunroof over none at all.
I guess the next best thing, would be to install the glass and ditch the mechanism. Not favourable because of the weight and issues with sealing around it without the mechanism and the drainage channels.
I settled upon an ally panel, knowing that the roof is going to be wrapped anyway so it won't be seen. Pros are lightweight and cheap, Cons are it looks a bit DIY - but Spitfires are riveted together and they're f
king awesome, right?
The hole
Cut myself an ally panel, punched and drilled it (sanded in a cross hatch style pattern, like a cylinder bore)
How it looks from inside once installed
And from the outside, after a quick polish
Many, many moons ago the sunroof cassette was ditched in the name of weight saving. It amounted to several kilos from high up in the car.
The right way to 'delete' the hole would be to get a roof skin from a non-sunroof Cav. This has not been possible, it seems that on even the most basic models most people opted for a manual sunroof over none at all.
I guess the next best thing, would be to install the glass and ditch the mechanism. Not favourable because of the weight and issues with sealing around it without the mechanism and the drainage channels.
I settled upon an ally panel, knowing that the roof is going to be wrapped anyway so it won't be seen. Pros are lightweight and cheap, Cons are it looks a bit DIY - but Spitfires are riveted together and they're f
king awesome, right?The hole
Cut myself an ally panel, punched and drilled it (sanded in a cross hatch style pattern, like a cylinder bore)
How it looks from inside once installed
And from the outside, after a quick polish
scottos said:
Looks cracking on those wheels, it was the only style for it wasn't it haha glad you like the ones on my 2002.
Exhaust wise, have you tried Krolltek? They are based up in Newcastle but I was pleasantly surprised at the workmanship v's price when they did my manifold.
100%, I think they finish it really nicely. I hadn't realised you were also going for gold split rims, I loved yours on the minilites and didn't think it could get much better, but the Image ones are another level mate. Exhaust wise, have you tried Krolltek? They are based up in Newcastle but I was pleasantly surprised at the workmanship v's price when they did my manifold.
I've not heard of Krolltek before, but a personal recommendation goes a long way. I think manifold wise I might now be sorted. A fellow GSI owner is having a complete exhaust made for his (BTB specs) and we are able to bring costs down by having one made for mine at the same time.
Jules Sunley said:
Excellent work as ever, and those wheels look fantastic. Great thread OP
Thanks mate, appreciate that. The wheels looks amazing and I'm blown away by the quality.Stick Legs said:
Amazing progress.
Love the alloy panel, nice bit of fabrication.
As much as I want to see it finished, I’ll be sad to have no more updates!
It's getting there for sure. The roof panel was a necessity driven choice, and will be covered externally by the roof wrap but it's growing on me. Love the alloy panel, nice bit of fabrication.
As much as I want to see it finished, I’ll be sad to have no more updates!
There'll be plenty of development over it's lifetime and it'll be getting hammered over the moors at every opportunity.
Polly Grigora said:
Getting very close now
Roof panel looks the part, top job Mr
Thanks mate. I'm quietly pleased that it came out ok, but I can't decide if it's totally gash or not. It'll be covered soon anyway. Roof panel looks the part, top job Mr
Very close now though, it actually looks like a car.
LankyMcTally said:
Ooof.
Love how it's coming together.
Me too bud, it's starting to look like I always hoped it would. Love how it's coming together.
Mark Benson said:
Been following since the start, it's all coming together very nicely now and I love the BBS wheels, very appropriate.
I have a feeling you're not too far away from me so I'll look out for it once you get it on the road.
They feel like the right choice, close to the originals but the road version which is how I see the whole car. I suppose I see it as a sort of Cavalier GSi homologation special rather than a race rep. I have a feeling you're not too far away from me so I'll look out for it once you get it on the road.
Original BTCC Cavalier wheels
Mine
I'm not sure where about in North Yorks you are, but one of my favourite ride/drives is Scarborough>Pickering>Goathland>Whitby>Scarborough with sometimes a brew stop at NY500.
Matter88 said:
Excellent build, I am an E36 die hard nerd but do like a Cavalier due to the obvious BTCC association.
I can recommend wholeheartedly AAS exhausts in Newcastle. They are racers themselves, and do beautiful work. Remarkably reasonably priced too and very nice people. I have used them previously for titanium exhausts for E36 M3, and E30 M3 race cars, and they're simply stunning.
Stuart is the man to speak to;
https://www.google.com/search?gs_ssp=eJzj4tFP1zfMS...
Thanks bud, appreciated. I also like an E36, one of my favourite threads on here was bennyc's track E36; I can recommend wholeheartedly AAS exhausts in Newcastle. They are racers themselves, and do beautiful work. Remarkably reasonably priced too and very nice people. I have used them previously for titanium exhausts for E36 M3, and E30 M3 race cars, and they're simply stunning.
Stuart is the man to speak to;
https://www.google.com/search?gs_ssp=eJzj4tFP1zfMS...
https://www.pistonheads.com/gassing/topic.asp?h=0&...
Thanks for the heads up on AAS exhausts, I'll maybe give them a shout (I'm just waiting to hear back on a manifold query) It's great to have so many options
CouncilFerrari said:
scottos said:
Looks cracking on those wheels, it was the only style for it wasn't it haha glad you like the ones on my 2002.
Exhaust wise, have you tried Krolltek? They are based up in Newcastle but I was pleasantly surprised at the workmanship v's price when they did my manifold.
100%, I think they finish it really nicely. I hadn't realised you were also going for gold split rims, I loved yours on the minilites and didn't think it could get much better, but the Image ones are another level mate. Exhaust wise, have you tried Krolltek? They are based up in Newcastle but I was pleasantly surprised at the workmanship v's price when they did my manifold.
I've not heard of Krolltek before, but a personal recommendation goes a long way. I think manifold wise I might now be sorted. A fellow GSI owner is having a complete exhaust made for his (BTB specs) and we are able to bring costs down by having one made for mine at the same time.
scottos said:
I loved the Minilites too so the new wheels were quite a big leap!
Krolltek are great, definitely worth a shout. Also LA Fabrication in Malton (i assume they may be closer to you as well, guessing you're somewhere over that way in N Yorks)
Ok mate, that's really good to know. It's good to have options, I came offshore this trip feeling a bit stuck with the exhaust and now I've got several. The power of PH, thanks lads. Krolltek are great, definitely worth a shout. Also LA Fabrication in Malton (i assume they may be closer to you as well, guessing you're somewhere over that way in N Yorks)
Malton isn't far at all, I'm Scarborough based.
Edited by CouncilFerrari on Friday 1st July 17:55
Cambs_Stuart said:
Fantastic progress. Really enjoying seeing it come together.
When do you think it'll be out on the road?
Thanks Stuart, appreciate that. When do you think it'll be out on the road?
I'm not sure really, I hope to be out by the end of the summer but I'm waiting on a manifold and once I get that I can get it booked in for the rest of the system, and once that's done I can book it in for rolling road and MOT... a lot of plates to spin but I'm trying to keep it going. Not helped by working away half the year though.
Davie said:
Agreed.
I've been quietly reading this from the beginning and with each update, my jealousy grows stronger!
It's going to be something rather cool and special once it's all finished - love the way it's going, wheels are a great choice.
Well played.
Well I am glad you like the updates, I think I've been quietly reading this from the beginning and with each update, my jealousy grows stronger!
It's going to be something rather cool and special once it's all finished - love the way it's going, wheels are a great choice.
Well played.
It is coming on well, it's getting there slowly and the wheels go with the overall theme and direction I had in mind. I wasn't sure but the more I look at them, the cooler it seems to be. Not that I'm biased!
Well, being summer holidays it wasn't a great time off for getting stuff done with the Cavalier. I'm kind of pissed off about it, because the year is creeping away from me and so is the good weather. Spending half my year in the North Sea is starting to look like a bad choice for getting project cars over the line.
Had a magic holiday with the kids though and I wouldn't change that for the world, so I guess the car can wait.
Anyhoo, as I previously mentioned there is another Cav GSI owner who was having an exhaust system made for his car. The chap making his system, offered to make a manifold for mine and use the other Cav as a template. The bonus being that it would bring costs down a touch, too.
Here it is completed and fitted;
Pretty blown away with it, made to SBD/BTB spec as well so should make good power.
Picked up a new runabout for the wife while I was on holiday, too;
Had a magic holiday with the kids though and I wouldn't change that for the world, so I guess the car can wait.
Anyhoo, as I previously mentioned there is another Cav GSI owner who was having an exhaust system made for his car. The chap making his system, offered to make a manifold for mine and use the other Cav as a template. The bonus being that it would bring costs down a touch, too.
Here it is completed and fitted;
Pretty blown away with it, made to SBD/BTB spec as well so should make good power.
Picked up a new runabout for the wife while I was on holiday, too;
Mr Tidy said:
Your exhaust looks like a work of art.
Thanks mate, it looks st hot to me 
Polly Grigora said:
Thank you for the update
As above, the exhaust is fantastic
No worries, I'm hoping the next one is better. A timed up engine, with complete wiring loom and ready for start up would be good! As above, the exhaust is fantastic
DuncanM said:
Everything is just so good, the exhaust is a work of art for sure 
It is looking smart now, I must admit. It's just doing my tits in that it's still not running and loose on the roads!Polly Grigora said:
Cheers
Looking forward to the next update
Me too matey, I can't wait to have it done now!Looking forward to the next update
Time for an update on the last few months of activity.
Following the delivery of the manifold, I tried to fit it and one of the exhaust studs unwound - the thread was fked. Anyway, a quick helicoil later and it was fitted. While the car was up in the air, I whipped the front wheels off and painted the front wheel arches with POR15, a job that had been on my to do list for a while.
Done;
IMG_0399 by Chris Cav, on Flickr
That's now every body bit metal under the car protected from the elements.
What followed was a few months of not much at all owing to work schedules and travelling overseas.
I did managed to get the alternator and PAS pump bushes stripped and painted though. Before;
IMG_0692 by Chris Cav, on Flickr
A bit of etch and some satin black;
IMG_0828 by Chris Cav, on Flickr
And some new zinc plated bolts and nyloc nuts;
IMG_0829 by Chris Cav, on Flickr
Brackets refitted to the car;
IMG_0830 by Chris Cav, on Flickr
Next up the PAS pump was flushed out, degreased and painted;
IMG_0877 by Chris Cav, on Flickr
IMG_0876 by Chris Cav, on Flickr
IMG_0875 by Chris Cav, on Flickr
Got a couple of new auxiliary belts;
IMG_0884 by Chris Cav, on Flickr
The old one looked a bit worn when compared to the replacement belt;
IMG_0886 by Chris Cav, on Flickr
Following the delivery of the manifold, I tried to fit it and one of the exhaust studs unwound - the thread was f
ked. Anyway, a quick helicoil later and it was fitted. While the car was up in the air, I whipped the front wheels off and painted the front wheel arches with POR15, a job that had been on my to do list for a while. Done;
IMG_0399 by Chris Cav, on FlickrThat's now every body bit metal under the car protected from the elements.
What followed was a few months of not much at all owing to work schedules and travelling overseas.
I did managed to get the alternator and PAS pump bushes stripped and painted though. Before;
IMG_0692 by Chris Cav, on FlickrA bit of etch and some satin black;
IMG_0828 by Chris Cav, on FlickrAnd some new zinc plated bolts and nyloc nuts;
IMG_0829 by Chris Cav, on FlickrBrackets refitted to the car;
IMG_0830 by Chris Cav, on FlickrNext up the PAS pump was flushed out, degreased and painted;
IMG_0877 by Chris Cav, on FlickrIMG_0876 by Chris Cav, on FlickrIMG_0875 by Chris Cav, on FlickrGot a couple of new auxiliary belts;
IMG_0884 by Chris Cav, on FlickrThe old one looked a bit worn when compared to the replacement belt;
IMG_0886 by Chris Cav, on FlickrNext job on the list - I had to make up a new brake servo vacuum hose. The fittings were different because when running the ITB's the threaded connection that's on the standard inlet manifold is missing.
The old pipe;
IMG_0879 by Chris Cav, on Flickr
And some snazzy red silicone vacuum hose. With fittings transferred over and installed into the car. Not necessarily it's final placement, I'll tie it into the loom tie off points once the wiring is finalised;
IMG_0881 by Chris Cav, on Flickr
I then fitted the radiator and fan/fan shroud assembly and coolant pipes. I was a bit nervous about this, as I was told the exhaust manifold was likely to foul the fan shroud. Thankfully, no such dramas and there's a good bit of clearance, well enough anyway. It's not touching is what matters!
IMG_0871 by Chris Cav, on Flickr
IMG_0872 by Chris Cav, on Flickr
The old pipe;
IMG_0879 by Chris Cav, on FlickrAnd some snazzy red silicone vacuum hose. With fittings transferred over and installed into the car. Not necessarily it's final placement, I'll tie it into the loom tie off points once the wiring is finalised;
IMG_0881 by Chris Cav, on FlickrI then fitted the radiator and fan/fan shroud assembly and coolant pipes. I was a bit nervous about this, as I was told the exhaust manifold was likely to foul the fan shroud. Thankfully, no such dramas and there's a good bit of clearance, well enough anyway. It's not touching is what matters!
IMG_0871 by Chris Cav, on FlickrIMG_0872 by Chris Cav, on FlickrAnd the last month or so has all been about fluids. I finished off the routing of the brake lines, installed the unions and flared the lines. Made up some little L shaped brackets to secure the braided line to copper joint to. Looks pretty smart I think;
IMG_0899 by Chris Cav, on Flickr
Ordered some brake fluid - ATE Type 200 - and then filled up the master cylinder and bled the brakes.
IMG_0901 by Chris Cav, on Flickr
I had one leaking flare, which I remade off and bled the brakes successfully until the pedal was solid. A decent achievement given that's a 100% brand new brake system. It's sat with the wheels off for a couple of weeks, hopefully when I get home there'll be no drips or seeps still.
IMG_0899 by Chris Cav, on FlickrOrdered some brake fluid - ATE Type 200 - and then filled up the master cylinder and bled the brakes.
IMG_0901 by Chris Cav, on FlickrI had one leaking flare, which I remade off and bled the brakes successfully until the pedal was solid. A decent achievement given that's a 100% brand new brake system. It's sat with the wheels off for a couple of weeks, hopefully when I get home there'll be no drips or seeps still.
While I was in the wheel arch fking about with the brakes, I noticed that windscreen washer pump looked a bit 'odd'. Turns out it was just waiting to fall apart on me;
IMG_0889 by Chris Cav, on Flickr
Managed to find a replacement easily enough, turns out the same pump is used by a Merc Sprinter.
IMG_0912 by Chris Cav, on Flickr
While I was there, I ran some new clear PVC piping in and installed the new pump. I now have washer jets that work which is another step towards an MOT pass.
IMG_0915 by Chris Cav, on Flickr
This is how it looked before I took the wheels off to sort the brakes;
CAVVY by Chris Cav, on Flickr
Really getting there now. I'm booked in with LAFabrication first week in April to have the rest of the exhaust made and the next few weeks I will be focusing on getting the wiring finished off, and getting fuel lines installed.
king about with the brakes, I noticed that windscreen washer pump looked a bit 'odd'. Turns out it was just waiting to fall apart on me; IMG_0889 by Chris Cav, on FlickrManaged to find a replacement easily enough, turns out the same pump is used by a Merc Sprinter.
IMG_0912 by Chris Cav, on FlickrWhile I was there, I ran some new clear PVC piping in and installed the new pump. I now have washer jets that work which is another step towards an MOT pass.
IMG_0915 by Chris Cav, on FlickrThis is how it looked before I took the wheels off to sort the brakes;
CAVVY by Chris Cav, on FlickrReally getting there now. I'm booked in with LAFabrication first week in April to have the rest of the exhaust made and the next few weeks I will be focusing on getting the wiring finished off, and getting fuel lines installed.
Edited by CouncilFerrari on Wednesday 1st February 18:57
B'stard Child said:
Might want to blank out your address on ^ that picture and re-host it
I'll edit my post when I see you've done it to remove the image
There are some bloody weird people around is all I want to say - Plus I'd like the car to stay in your care
bI'll edit my post when I see you've done it to remove the image
There are some bloody weird people around is all I want to say - Plus I'd like the car to stay in your care
ks! Thank you for pointing that out, picture and post edited! I'm normally pretty alert when it comes to persec type stuff. Thanks again, I appreciate the pointer.
Gassing Station | Readers' Cars | Top of Page | What's New | My Stuff