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sleag40

Vauxhall Cavalier

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sleag40
18 hours ago, Duffy said:

Great stuff!

 

Obviously completely horrified you didn't sort that during the big strip down!

 

:D

Haha! It was fine last year, the extra thousand miles done since last August must have worn it out!

7 hours ago, Alex said:

Nice work! I've driven the Mk1 Cavalier in Vauxhall's heritage collection - it's a decent drive, I was surprised at how good it felt. Vauxhall's Mk2 is an auto, though. I remember friends' parents having them when I was a kid. Felt like stepping back into something familiar, which the Mk1 didn't. 

Cheers Alex! The mk2 drives like a modern car - surprising given the 36 years since it's launch. The Mk1 is definitely from a different era though, I still prefer the way the Mk1 drives over the Mk2 - even though the Mk2 would be a lot nicer to live with day to day.

Edited by sleag40

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sleag40

Tax free status now achieved :) It wasn't as straightforward as it should have been though. I took all the relevant bumph to the Post Office, only to be told that for some reason or other they couldn't do it. A phone call to the DVLA revealed the reason why - they had the date of manufacture for the car down as 31/12/77. The car was registered on 04/01/77, so there had clearly been a mistake made somewhere! They couldn't sort it over the phone, so I had to post a V10, my V5C and a cover letter to Swansea, and a couple of weeks later, the job was done.

20170525_165948_zpskx0ndwsg.jpg

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vladales

I am so glad that this project ended up this good. Well done, I like it so much. My project is still on hold, I am collecting parts. :)

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sleag40
On 20/06/2017 at 20:35, vladales said:

I am so glad that this project ended up this good. Well done, I like it so much. My project is still on hold, I am collecting parts. :)

Thank you kindly vladales! I'm looking forward to updates on your Zastava, hope you've been busy!

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sleag40

MOT done today, still pretty clean under there apart from some dusty bits! :)

20170810_081954_zpsx6ltfdaj.jpg

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sleag40

Not updated for a while - still getting a bit of use out of this old bus.

 

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Just put it away for the Winter. 😞

 

The mk2 got a years use until the MOT ran out at the end of March, and it sat around for a few months until I made a start stripping down in October.

 

 

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sleag40

First up, it got a wash...

f168f666994f.jpg 

Very dusty after a few months in my lock up!

159cdf5ff847.jpg 


Had a bit of a pick at the O/S rear arch  - as expected, its far from pretty! Its just as it looked - repair panels tacked on followed by lashings of filler. Where the inner arch met the outer lip, a good inch of filler was used to stick the two together.

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Just this one small scale excavation has instantly made me appreciate the fantastic condition my MK1 came to me in! 
The interior and carpets wiould be stripped out next to hopefully ensure that I won't be wasting my time by repairing the arches, rear valance and sills. 🙂
 

Edited by sleag40

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sleag40

Made a start on removing the interior.

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Spare wheel hasn't seen much action, Jack and wheelbrace present, but tools missing.

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Spare wheel well is pretty good - a couple of rusty bung holes, but good and solid, and will clean up nicely.

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Near side wheel house looks pretty good now the rear interior trim is out.

 

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Theres a little bit of rust peeking out between the boot floor and the off side wheel house, it doesn't appear to be soft, and withstood a good stabbing with a sharp screwdriver. This will be properly investigated at some point.
So far, so reasonable! 🙂
 

Edited by sleag40

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sleag40

Couldn't resist a good old pick at the rear valence....

efe4e5e3d214.jpg 

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Pieces of metal have been tacked on and wobbed over, it took a decent amount of biffing with a hammer to break it, but I would imagine it being a bit 'cornflakes box" in an accident.

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The front seats, centre console and assorted trim pieces were removed to allow the carpets to come out.

 

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A long time was spent vacuuming all the dog hairs and other crap out of the carpets - they came up pretty nicely.

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Had a look under the underlay and found a Stanley knife blade that had stuck itself to the foam part of the underlay. I assume that it was left in there during assembly, as nothing appears to have been disturbed inside the car until now.

a5493c632389.jpg 

Edited by sleag40

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sleag40

After removing the rear bumper, I continued peeling away pop riveted "repair" pieces and chipping away at the filler. 

(54b599de5d89.jpg 

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The inner parts on the lower rear quarters and rear valance have been bodged in the same style as the outers. This will all be removed at some point, and started again with sheet steel and welding instead of pop rivets and wob!
I could do with some pics of what it should all look like before I get stuck in to make sure it all looks right when done.

The front bumper and lower spoiler type thing were removed next to reveal very crispy wings and edges of the front valance where the wings attach.

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I could probably repair the valance, but it looks like I could do with a pair of wings. 😞
 

Edited by sleag40

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sleag40

Good news came next - a genuine front valance panel had been sourced.

b29f005c681c.jpg 

Should save a bit of time straightening and repairing the original part, and go some way towards making this sad face look a bit happier. 🙂

 

IMG_20181027_122116.thumb.jpg.036e3cf324ff12fee5aa0bea46348870.jpg 

Edited by sleag40

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sleag40

Next up, wings, arch liners, rear side glass and roof gutter trims all came off. The driver's side front wing may well be past saving, but the inner wings seem to be pretty reasonable so far (may be some small repairs needed after its seen the wire wheel!)

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The passenger side wing is much better - I'll possibly be repairing the lower front section on this. The inner wing on this side looks pretty much spot on (wire wheel notwithstanding) 

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The sides of the panels behind the headlights have rotted, and will need repairing - hopefully it won't be too difficult to make a nice job of it. 🙂

 

IMG_20181108_173000.thumb.jpg.c85c71663668e580bd06a20eccf2d001.jpg 

Edited by sleag40

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sleag40

Next installment was kicked off by removing the tail lights and number plate panel.

ba4449a18746.jpg 

After that, I couldn't resist it any more - the grinder came out, and armed with a wire wheel, flap disc and slitting disc, the O/S/R outer arch "repair' came off 

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There's not much left of the outboard side of the inner arch once all the structural filler and mesh came off!

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I was hoping that there was more inner arch left than that - its gonna be a bit of a mission to remake that so it looks right! Hopefully I can modify a wheel tub for a different application to make a decent job of this as a replacement doesn't appear to be available! 

 

IMG_20181113_180310.thumb.jpg.24cfc7fc00fef3c25bc91d49daad6590.jpg

 

If anyone knows of a replacement inner arch panel for sale, I'd be fantastically grateful as it would save me a fair bit of time!

Edited by sleag40

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sleag40

A bit more excavation - the dubious repairs to this side were a fair bit easier to remove due to being attached with pop rivets instead of welding.

 

IMG_20181114_175518.thumb.jpg.88a71b0f73022433c4451bdec8a0c3c4.jpg

 

There's a lot more inner arch left on this side, but the rearward end visible in the next pic is another pop riveted repair yet to be ousted.

85fddc021cbc.jpg 

Because the wheel arch came away so easily, I had enough time left to have a pop at the rear valance. Should be an easy enough job to repair this - I have an outer panel, just need to replace the bottom inch or two of the inner part.

2f9ad045a283.jpg 

Bonus shot of some of the junk that has parted company with the car recently.

f710d8473116.jpg 

Edited by sleag40

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sleag40


Collected a decent pair of genuine wings to avoid repairing my proxy ones.

 

IMG_20181118_135957.thumb.jpg.d4a45e06170f53a1c5dda6c3f34dde66.jpg

 

They were a long way away, but the pair were less than half the price of one new GM wing. 🙂

3b22fd31b742.jpg 

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No more actual work done that day, but less bran flakes to contend with can only be a good thing!
 

Edited by sleag40

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sleag40

Armed with a couple of hours spare last week, I prepared myself for the deep joy of dashboard removal. I don't have a steering wheel puller, so hit it with the violent wiggling trick. After a few minutes of that, coupled with a bit of professional grade language, it popped off.

83116dab4de3.jpg 

As is normal, the Haynes book gave me a few clues, but I had to work out how to remove some of the parts which ate up a fair bit of the time available.

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Once I'd discovered how to remove the passenger side air vent, radio and central vents, the operation sped up somewhat.

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And its out! 🙂

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Took out the comedy air vent ducting (similar to the MK1)

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I'd run out of time now, so had to leave the heater box and wiring spaghetti for another day. My target for the day was to get the dashboard out though, so jobs a good 'un!

 

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Up to date now, will update as and when from now. Probably be new year before I'm back on it.

Edited by sleag40

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Duffy

Great stuff, nice to see it done properly 

 

🙂

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kiran_182

Wondered what was going on with this 

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sleag40

Grabbed an unexpected bit of stripping time on this earlier - the bumper brackets, side repeaters, mirrors, wiper arms, windscreen trim, door membranes + removable parts of the grill all came off.

IMG_20181204_183420.thumb.jpg.646ae5d66aaf6e7d67a0697857893ef2.jpg

Window bottom trims were next - great care was taken to avoid distorting these as they're made from a soft alloy - I seem to have gotten away with keeping them nice and straight. 🙂

34cbb3146d8c.jpg 

More progress to follow sporadically!

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sleag40

🙂

Another bit of unexpected time spent on this back in December - I decided to do a bit of bran flakes banishment - and thought I'd ease myself in to it by tackling something non structural + hidden from view when completed. (Just so I could experiment a little!)

First pox patch pruned

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Making a replacement piece

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Welded in (a bit of hole chasing occurred, no doubt due to the poor condition of the metal I was welding to in some areas)

 

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The other side was done in a similar style

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Once the replacement piece was shaped, I decided to postpone the welding until I've grabbed my 0.6mm wire from home. I'm thinking the lower power required to melt it may make it less likely to blow holes in the poorer patches of metal.

43c1af5d4b24.jpg

Edited by sleag40

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sleag40

Day off today - so pencilled in a couple of hours on this heap. 🙂 First up, the bonnet came off in preparation for removing the engine/gearbox at the weekend. (time on two post ramp permitting)

 

ccfd91c03e5d.jpg 

Next I decided to remove the outer part of the front valance. I was going to replace it in its entirety, but it would be difficult to weld it on without unsightly beads on the end of the chassis rails. This way I had the joy of unpicking all the spot welds holding the front part to the beam behind it. (And look forward to separating the two parts of the GM replacement!)

 

IMG_20190205_141710.thumb.jpg.93ddb801f87de50827c973b12fe2e697.jpg

 

Before leaving, I ran it up until the fan had kicked in a couple of times. I was totally impressed that it started immediately after a couple of months festering!
 

Edited by sleag40

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sleag40

Whilst waiting for my mate's ramp, I removed the windscreen. It has a few chips in it from the time a truck flicked a load of gravel up at it on a motorway slip road last February, so I'm on the hunt for a replacement. The screen frame has no rusty bits at all which was a bit of a bonus. 🙂

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Then the engine and box came out with the gratefully received assistance of our kid. (He did his apprenticeship at a Vauxhall dealership when these were new)

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Its now sat piddling it's oil out onto the floor.

70e15b3a4996.jpg 

Edited by sleag40

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sleag40

Got a bit more time in on this today - under bonnet furniture removal time.

b4edb4652d10.jpg 

Haynes manual yielded the odd indication on how stuff comes apart. (not many)

0892872c8bc8.jpg 

Removed a sheet metal/filler/sheet metal sandwich "repair" to the offside inner wing behind the headlight.

7665ba803be0.jpg 

Finished the session off by unpicking half of the reinforcement part of the replacement front valance.

c848e450faba.jpg 

I'll finish the other half next time! 🙂

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sleag40

Most of the front suspension gubbins came off after work today.

79685cb83b44.jpg 

Its getting closer to the stage where I can get it up on a rollover spit. The brake lines and servo, plus the steering rack will come out next, then I can remove the bulkhead cover and have a good check for car pox.

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Last week I discovered the reason for the jerky gearchange experienced when it was in use....

9bf71fc904a6.jpg 

The front gearbox mount was broken - a new one has been sourced already. 🙂

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kiran_182

Thorough work as always 

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