VAUXHALL ASTRA GTE MK1 CAR PERFORMANCE SPORTS TURBO
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4X4 MK1 VAN
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PAULDRIVER
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Posts: 261
Location: HORBURY, W.YORKS

PostPosted: Tue Apr 26, 2016 5:25 pm    Post subject: Reply with quote

Cheers, it makes me grin also, makes me grin more when i think about actually driving the thing big grin

A few pictures from this morning of underneath, and of the toyota chassis where we are joining it to the van.



The sills are not too far away for starting with.














Back end
















Found out project binky is using the older gt4 1989-94
Mines the newer updated version 1994-99,
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PAULDRIVER
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Posts: 261
Location: HORBURY, W.YORKS

PostPosted: Tue Apr 26, 2016 6:42 pm    Post subject: Reply with quote

Last few photos on the ramp as she is back on the floor tommorrow,
Decided to do the sills on the floor,

The toyota chassis is now joined to the van at all 4x points front and rear.
Front




Rear




Outer sill ready to be joined to the toyota inner


Only the sills and a few little bits then all welding is done Dancing
Going to be cleaning EVERY weld up as best i can, once its stone chipped and painted, as well as all the running gear, it will look the dogs danglies.

Will put some more pics up as i go.
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PAULDRIVER
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Joined: 08 Oct 2010
Posts: 261
Location: HORBURY, W.YORKS

PostPosted: Thu Apr 28, 2016 6:32 pm    Post subject: Reply with quote

Decided to leave the welding for now, and start mock fitting the radiator and charge cooler, we did manage to half make the front cross member, this will be removed and finished off.
we used a corsa B rad which is thinner and fits better, we had to do away with the HUGE manifold from the turbo to give us more room, big grin



Modified the gearbox cradle to fit our cross member, again this is all work in progress. but looks like it will work ok.







Managed to move the gearbox oil cooler onto the gearbox and looks like it should be ok, will need a couple of pipes making up though, (normally a dear do)




A picture of the cross member.




Just need some captive nuts then thats another job off the list
Applause


Will be doing various bits on the van now, but ill put some pictures up for you to have a look.


Last edited by PAULDRIVER on Sat Apr 30, 2016 4:28 pm; edited 1 time in total
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gazster
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Joined: 09 Aug 2009
Posts: 654
Location: yorkshire

PostPosted: Thu Apr 28, 2016 8:56 pm    Post subject: Reply with quote

I carnt wait for this to be done gonna be one quick van,you make it look like a walk in the park at the speed your getting it done eek
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PAULDRIVER
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Joined: 08 Oct 2010
Posts: 261
Location: HORBURY, W.YORKS

PostPosted: Thu Apr 28, 2016 9:21 pm    Post subject: Reply with quote

It is coming along nicely, having a rest from welding for a few days,but only the sills left now now.
Just starting to pipe the motor up and put all the wiring back in, see what we need and whats getting done away with, in an earlier post i said i need to use the gt4 heater and some other parts but wired up to mk1 switches in the mk1 dash,

I dont know if i can use the mk1 indicator and wiper levers yet, i want as much mk1 as poss, but we ll cross that bridge when we come to that railway crossing big grin

Will put some more pictures of the build. bounce
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PAULDRIVER
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Posts: 261
Location: HORBURY, W.YORKS

PostPosted: Fri Apr 29, 2016 7:42 pm    Post subject: Reply with quote

a few pictures of the wiring.







The loom sits nice between the cross member and front panel




Fuse box and relays, which had to be made smaller to fit cool


This is loosely in


Had to move the gearbox oil cooler as the chargecooler pump sits in that space, we are wanting to get it running soon then sort the lights etc...
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PAULDRIVER
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Joined: 08 Oct 2010
Posts: 261
Location: HORBURY, W.YORKS

PostPosted: Tue May 31, 2016 10:52 pm    Post subject: Reply with quote

We ve still been getting on with the van in the last few weeks,
It s been nearly 3 weeks waiting for the chargecooler rad to be made,
Havent been able to mount the rad or anything because of it which has just wasted time i didnt want to.
But it should be here tommorrow wednesday so i can do more,
heres a few pictures of the sills that are now done and look mint, i will put some more up.









The sills are welded up and ground down, they are not the finished article yet but look really good, its as if the Toyota and GM technicians knew i would be doing this build laughing







managed to fit all the front end on and line up the wings and bonnet,
fitted the lights and indicators to make sure all is good, which it is big grin
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PAULDRIVER
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Posts: 261
Location: HORBURY, W.YORKS

PostPosted: Wed Jun 01, 2016 6:39 pm    Post subject: Reply with quote

Missed the postman so didn t get the chargecooler till 5 pm mad

Heres a few pictures of all the seams ive opened up ready for when its dipped, ive done round the windscreen, doors and tailgate, and about 95% is rusty and will eat itself inside out if nothing is done, you can see what i mean in the photos, once i started i kept finding more and more surface rust, so i kept going till id opened up between every spot weld i could find,

It is very satisfying to know this van will be around in another 30 years when ive done with her. big grin

Here we go...





























This is what you need to do to yours, as its bare metal with no primer in between, as you can see it is not pretty,
Im priming it then closing them up with the hammer and block, then when its painted im sealing over with waxoyl (lots)

I d bet £1000 they re all the same in there.
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tuffty
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Joined: 25 Oct 2005
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Location: Ipswich

PostPosted: Wed Jun 01, 2016 9:48 pm    Post subject: Reply with quote

Top job.
What are you planning for the arches as the wheelbase looks a fair bit wider?

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PAULDRIVER
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Joined: 08 Oct 2010
Posts: 261
Location: HORBURY, W.YORKS

PostPosted: Wed Jun 01, 2016 10:31 pm    Post subject: Reply with quote

Ive got some 16" steel wheels from a seat that fit,

These toyota wheels are offset for the massive sills and rear quarters,

Its surprising the inner sill to sill is the same as the mk1.
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PAULDRIVER
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Joined: 08 Oct 2010
Posts: 261
Location: HORBURY, W.YORKS

PostPosted: Thu Jun 09, 2016 6:20 pm    Post subject: Reply with quote

Some more pictures of the build from today.
Managed to fit the radiator, and our chargecooler rad we had made for the job. Also got all the front lights and indicators working big grin



We will be bolting the strengthener between the slam panel and lower, so you can remove the rads without taking the turbo off etc...









O/S side light wired up with mk1 bulb connectors !


N/S side light wired up with mk1 bulb connectors !


Headlights wired up, both main and full beam work with mk1 bulb connectors !


These fans are half price of those kenlowe ones, when we wired them up we could feel the suction so tried to see if a rizla would stick to it ?
It actually holds the full pack as well !


Mk1 fillers on the right and the toyota is left, and as we are using the toyota tank, the spout for the tank is just underneath and couldnt go in a better place really, so i chopped the toyota filler cap pipe down from 18" to 5" and joined it with some rad hose about 4" from cap to tank, we loved it when we saw where it landed big grin big grin big grin


Original gt4 filler cap seals beauty and doesnt stink of petrol inside the van


We cut the back of these holes on the front panel to open the up for more airflow to the rads, every little helps as they say smile


Top photography work here for you guys !
Managed to photo the indicator whilst in operation !!!
With a delay on the camera !!
Did it in 3 goes.


The other side does work i promise.
Heres another addition to the VBOA fleet


Im wanting to build something like this

https://www.youtube.com/watch?v=j50KLqZi6B8
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PAULDRIVER
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Joined: 08 Oct 2010
Posts: 261
Location: HORBURY, W.YORKS

PostPosted: Sat Jun 11, 2016 6:09 pm    Post subject: Reply with quote

Fitted a dash and drivers seat to see how the steering column went, and it is good, ive had to get a boss to fit this wheel and the toyota column, its an old school opel wheel i bought from germany about 4 years ago





The column just tacked in here, but when we finally decide, we ll make a bracket up for the column to bolt to, the toyota column is adjustable so even better for getting it where you want big grin

It is ready to drive now ! Cool
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PAULDRIVER
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Joined: 08 Oct 2010
Posts: 261
Location: HORBURY, W.YORKS

PostPosted: Mon Jun 13, 2016 6:44 pm    Post subject: Reply with quote

Had a look through our "spare parts" to see which heater/blower would be suitable as the toyota one is huge and wont fit behind the mk1 dash, i so wanted to fit the aircon, but the bastxxd wont fit mad
So we decided on the austin mini, which is a complete unit with heater matrix and fan altogether, just the inlet and outlet to pipe up, and the 2 pipes up to the screen, the other 2 blow down, this isnt the actual one im using, ive found a plastic version off a later 1996 mini so is a bit lighter and wont rust like this one.









There was loads of electrical gadgets not needed from the toyota, so a bit of a task removing it, but we got there big grin
Heres the pile


Going to be doing the rear lights and fog light tommorrow,
Got some bits from OPEL PARTS GREECE, these connectors are rarer than rocking horse sh$t !! Thanks i couldn t have done it without you Cool





Found out my chargecooler pump is seized and wasn t working, so wasnt cooling ! it should fly when its working, it did when it wasnt !

We are hoping to drive it this week as it is ready now.


Last edited by PAULDRIVER on Sat Jun 18, 2016 11:13 pm; edited 1 time in total
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PAULDRIVER
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Joined: 08 Oct 2010
Posts: 261
Location: HORBURY, W.YORKS

PostPosted: Fri Jun 17, 2016 6:15 pm    Post subject: Reply with quote

A few more pictures for you !
Managed to wire the rear lights, reg plate light and fog light.
The list of jobs to do is getting smaller day by day smile




Fog light wired up to the mk1 fog switch, rear lights working off the toyota stalk.

Heater blower fits nice




Managed to fit the rear seats as well.
big grin big grin big grin
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GT/Estate
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Joined: 30 May 2005
Posts: 2230
Location: Rotherham

PostPosted: Fri Jun 17, 2016 8:00 pm    Post subject: Reply with quote

Ace project, is this going to be a road going car or just track?

Want to do something similar with my omega and the front end of a 3dr with the back half of a 5door to match the omega wheelbase and make a stretched mk1

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