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There is no replacement for displacement
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2,175 Posts
Discussion Starter #1
This is a WIP thread for my 'Supercav' (named tongue-in-cheek by a mate, and it's stuck!).

The car will be all the best 'goodies' from a couple of Cavs I used to own:

My old 2.5 V6 workhorse (this donated its interior, ICE, and some of the creature comforts):





My old 3.0 V6 (this donated engine, box, running gear, exhaust, inspiration!):





...into a cracking donor shell I've picked up, which is currently an N reg 2.5 V6 with only
64k on the clock. It was previously owned by an old guy who must have taken it to the main dealer for everything. It doesn't even have the 'standard' Vauxhall oil leak!

Photos of when I first bought it:


















Old fanblades gone and replaced:



The plan is to turn this pile of bits:



...into something a bit more presentable and get it all onto the car!

So far I've got the engine cleaned up and painted:







and the gearbox also sorted:





Unfortunately I've been distracted from this project for a while, but I'm back on it now and my (slightly ambitious!) plan is to get it done and on the road ready for Billing this year. Place your bets please!

So this evening I prepped the car for a windscreen change:



I'll be having the perfectly serviceable OEM screen taken out and replaced with this (heated windscreen):



Here's a random shot of the interior - the cloth seats/doorcards have been sold and will eventually be replaced with a set of Cav turbo leathers:



Intended spec:

3.0 V6 engine with uprated FPR, lightened flywheek, and Omega inlet system.
F28 Box with LSD.
Lowering springs and adjustable shocks, polybushed suspension.
Manifold back custom stainless steel exhaust.
308mm front brake conversion.
Sequential LPG conversion.
Cav turbo interior.
GSI bodykit.

and lots of other goodies!
 

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There is no replacement for displacement
Joined
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2,175 Posts
Discussion Starter #6
Hope we see it in July chap!

Looks like it'll keep you busy though...
Yes, I'll be at Billing one way or another anyway. I'd just prefer to show up in the Cav rather than one of my current VW fleet! But I'm already behind the plan, lol!

Also, Hatchback... :(
This car is going to be my daily driver, so it has to be hatchback. Saloons are great for additional stiffness, but totally gay when it comes to getting something big in the car!

Them rear arches look totally rust free ! Lol ....
Not quite rust free, but that will be sorted before it hits the road. I'll be giving the underside a good clean/wayoyl/undersealing to keep it that way too!
 

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There is no replacement for displacement
Joined
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2,175 Posts
Discussion Starter #7
Today's progress was getting the heated windscreen fitted, which is now done:



...thanks to Doktor Glass, a company in the East Midlands who specialise in old cars and the like. Unlike a lot of the other companies I contacted, they were totally unfazed by what I wanted, and got it done great (and were also the cheapest, which is a bonus). They also managed to get the old screen out in one piece, if anybody wants a cheap replacement Cavalier screen?

Made a start on sorting out the LPG tank ready to get fitted. Not the most important job, but I'm sick of tripping up over it, so it kills two birds with one stone to just fit it into the car!
 

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There is no replacement for displacement
Joined
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2,175 Posts
Discussion Starter #9
Where did you get a heated screen from? I thought Ford hogged them all for themselves and the brands they used to own.
The screen is made by a guy called Ricky in Tamworth (I can't remember his business name). He makes heated screens for loads of different cars, and was really helpful when it came to wiring it all in. He does have a few more Cav screens in stock if anyone is interested, his number is 01827283688.
 

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There is no replacement for displacement
Joined
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2,175 Posts
Discussion Starter #11
In my early Cavweb days, I remember C3MKY (IIRC) organising a group buy for a batch of aftermarket Cav Mk3 Heated Front Screens.
It was probably this guy who made them - unfortunately a few people dropped out of the group buy and the guy has been left with them.
 

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There is no replacement for displacement
Joined
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2,175 Posts
Discussion Starter #12
Today's progress wasn't earth shattering as I got in from work late. However, the LPG tank has gone from this:



to this:



which is a big improvement! Next trick is to fit it; I've got a busy couple of evenings ahead, but hopefully I'll get chance to fit it before the weekend....
 

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There is no replacement for displacement
Joined
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2,175 Posts
Discussion Starter #13
Didn't get a lot done on the car this weekend as I've been distracted by a lot of other stuff, and the carport has been like a greenhouse in the hot weather, but I did manage to get the LPG tank all but fitted. Started off with the standard view:



The floor- pan is in amazing condition with no rust whatsoever:



Now it looks like this:



Before I dropped the tank in, I zinc primered where I removed the spare wheel holder, to stop it going rusty, and put in rubber strips to help reduce noise and also leave a small air gap between the tank and the bodywork as condensation will form on the tank. I also popped out all the bungs to allow condensation to drain out of the spare wheel well.

Before I can secure the tank, I need to make a plate up to go underneath the car, and get a a hand from someone to tighten the bolts up.

The plan for tomorrow is make a start on the engine.
 

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There is no replacement for displacement
Joined
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2,175 Posts
Discussion Starter #14
This evening I made a start on the engine, which was a mix of unpacking boxes to sort out the parts of the jigsaw puzzle:







It's a bit of a mess as I've stripped a Vectra V6 engine, Cav V6 engine and hoarded parts, so it's hard to know which bits are from what! I'm sure I'll have a few spares left once I've built it up! I might even do a trial build to make sure it's complete first.

Then I got the engine out. Although I painted it about 6 months ago, it was showing signs of rust bubbling up under the paint so I gave it a once over ready for another coat of paint to tidy it up:



 

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There is no replacement for displacement
Joined
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2,175 Posts
Discussion Starter #16
Spent a fair bit of time over the Bank holiday on the car. Tedious job of cleaning and painting!

First had to get all the grime off - all the nuts and bolts soaking in a bucket of vinegar!



Cleaning up the engine parts:





The silicone in the engine mounts had perished and come away from the rubber mountings, so this came out:



cleaned up the mounts then I refilled the gaps with fresh silicone. Not too bothered with the colour as it will all be getting painted anyway:



Most of the parts with a coat of paint:




Next part of the plan is to drop the engine and box out of the car, which will hopefully be happening over the next few days.
 

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There is no replacement for displacement
Joined
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2,175 Posts
Discussion Starter #19
Made some massive progress today! The 2.5 V6 engine and box is now out of the car and ready for collection. Managed to get it out without any issues or damage to the car, didn't even bother dropping the rad out (which is a mission on the V6's due to the electric recirc pump). Even had some time to trial fit the Omega inlet on the old engine to see what work needs to be done to make it fit (not a lot really).
Big thanks to my mate Ben for giving me a hand and bringing the donuts!

The pics can do the talking:















 

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There is no replacement for displacement
Joined
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2,175 Posts
Discussion Starter #20
Made some progress over the past few days, in amongst other stuff. Didn't get too many photos though.

Removed the radiator and PAS pipework as this is knackered in places and I may well be re-routing it where the battery tray is, if I can successfully make the battery tray removable.

Took a load pf bits to the powder coaters, and also an aluminium welder regarding changes to the engine mount, Omega inlet and inlet piping.

Following the chat with the welder, I got cracking on this:



Did what I needed too, then decided that the plenum generally needed a tidy up, as there were some pretty shonky casting joins etc on it. After and hour or so of hearty grinding, sanding, and eating aluminium filings:



...and one of the perks of living on my own:



Hopefully get it to the welders tomorrow for some blanking/mods.
 
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