1971 ND Nova MkII Restoration (56k Warning)Paddy |
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 Elite Veteran Posts: 837    Location: Gillingham, Kent | For those interested in what I'm doing on the project car. These photos are now a little out of date, and I will be able to take more over the next few weeks to show progress to date as it's moved on a fair bit! How its stored on a day to day basis - cramped but out of the rain!
Partially stripped interior
Wiring from hell - thats got to go!
Why the windows need replacing;
Why the headligth covers need replacing!
More interior;
Hydralics to be binned in favour of linear actuators for the roof;
Fire Hazard!
Fire Hazard!
OMG!
Hmmm, whats this here peice of string doing?
Ohhh - holding the gear linkage in, naturally! f**ing bodgtastic!
ahh - some holes, i better clean that up to see how bad
more holes - big ones
and even more - not looking good
Ahh - i thought that metal floorpan felt funny, that because its made of fibreglass!
Lots of holes under the fibreglass, infact one might say chasms
Only one thing for it - mwahahahaha
MORE MORE,mmmm burning!
What a waste of time!
Anyway it turns out to be soo bad that the entire floor pan on both side needs replacing - but at £25 a side i'll live with it! More pics to follow - body is off the chassis now P | ||
| jon8oy |
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 now on 2 wheels Posts: 7576   Location: back in longbridge b31 | i was wondering about what happend to this i thought maybe its still out side ur house looking sorry for its self  good work mate keep it up  | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | It was for the best part of a year I'm determined to get it done by the end of the year now though. It's alot of work though Todo: And the million and one other things that you never find until its all in pieces! | ||
| Metromartin |
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 MP Admin Posts: 17870 Location: Gloucester | what engines are in these things? intresting car though, shame its got more rot than a metro, Fancy another 1.8 banham one day?  | ||
| Snoopy16 |
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%20(450%20x%20338)4cec.jpg?memberid=1741&type=profile) R118 BRG GSi PC PLOD Posts: 9008 Location: South East Leeds | Jesus M8, that is rot!!!   | ||
| MG mick turbo |
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6ca0.jpg?memberid=1148&type=profile) Regular Posts: 142 Location: Newcastle Upon Tyne | |||
| grey54321 |
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| Veteran Posts: 309 Location: Steel City Sheffield | |||
| petrol_head |
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 drive it like its hired | that looks mental what lump is it/was it running? | ||
| Paddy |
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Basically it's a 1971 VW Beetle underneath, so it's all really simple 1930's technology. It had a 1500 twin port running twin 40's (1 per cylinder bank) and dual cannon exhaust. I'll be rebuilding it with 1641cc Barrels and pistons and racing sump. Might fit the porsche cooling gear at some stage aswell, but will see how it goes as is first. The engine is aircooled not water cooled for those unfamiliar with bugs. This is as it was:
and it will end up looking very similar but with slightly different internals It's LOUD - i mean over trackday noise limit loud! Looks like this (before taking apart!):
I'll be working on it again tomorrow - hopefully winching the body off the chassis - so there may be some amusing pics of levitating bodywork in my garage ceiling On the plus side the new floors have arrived! On the down side I cracked the acrylic glass when drilling the new screw holes | ||
| Ben_CAB |
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 Metro mad will do Posts: 3306  Location: SE London/Kent | |||
| FreddieS |
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 Elf eating dog breeder Posts: 10531 Location: Guildford | |||
| petrol_head |
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drive it like its hired | |||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | UPDATE: Here is the progress as it stands this evening; Old floors out Pics;
Special thanks to my 'technical consultant' - Mad Chris! It's coming along nicely, progress is good at this stage - i'm lucky to be having some time off work in order to do all this! All comments / suggestions appreciated! P | ||
| Paddy |
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Elite Veteran Posts: 837 Location: Gillingham, Kent | |||
| JamieS |
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| "MG Metro 1300" Location: Warwickshire, UK | Have to say thats one really ODD looking car  But should be a nice little car when completed  | ||
| FreddieS |
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Elf eating dog breeder Posts: 10531 Location: Guildford | |||
| chris_evz |
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 aka chris_evz Posts: 2726 Location: brynna south wales | |||
| Alex G |
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 Elite Veteran Posts: 929 Location: Maidstone Kent SE UK | Hey Paddy you may or not know that thats not the only Nova in Maidstone. I see a red one every day that drives past my work in Parkwood. Imagine one of them as your daily driver... what a legend | ||
| nig33 |
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| On a final warning Posts: 457 Location: here, there, everywhere | |||
| vvc warrior |
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 Retired Admin Posts: 15557 Location: Co. Durham North East | nig33 - 6/6/2009 3:13 PM any updates, this looks cool as penguin piss you doing a bit of grave digging there like | ||
| nig33 |
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| On a final warning Posts: 457 Location: here, there, everywhere | |||
| vvc warrior |
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Retired Admin Posts: 15557 Location: Co. Durham North East | |||
| nig33 |
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| On a final warning Posts: 457 Location: here, there, everywhere | |||
| Hawkes41 |
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02d9.jpg?memberid=3614&type=profile) Veteran Posts: 461 Location: Warwick | |||
| Paddy |
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Was dead Project is restarted, you just can't kill me mwahahahahaha Took me about a year to remember my password though Proper update to follow, but for now photos:
Not even sure if there is anyone left on here who remembers me or the car tbh, but who cares we're all car nuts right? How it once looked, and will again, or better!!!
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| 100Vi |
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| jon8oy |
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now on 2 wheels Posts: 7576 Location: back in longbridge b31 | hello paddy | ||
| Paddy |
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Hello! Yes the roof comes up on hydralics to let you in;
Now at Southways Automotive, sharing the stable with a couple of other 'interesting' projects
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| SubbyGTi16v |
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 Elite Veteran Posts: 732 Location: Towcester | Fond memories of this car parked outside my house and the trip up to the kent Kit car show at detling. Must dig out the pic of my lad sat in the drivers seat. How's it going Paddy ? long time no speak or see. Been many a year since your banham ventures too, I have only just got the Gti back on the road myself after 5yrs or so. Sadly I'm no longer live down in Kent  All the best Will | ||
| redgrave66 |
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 purple_metty Posts: 2165 Location: leicsestershire | i spy an ultima and a hillman imp! I used to work on the british privilige gt ultima.. nice | ||
| FreddieS |
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Elf eating dog breeder Posts: 10531 Location: Guildford | |||
| cerbera |
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 Forum Admin & Insurance Guru Project Pride Posts: 5690 Location: Durham - North East UK | |||
| Paddy |
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Elite Veteran Posts: 837 Location: Gillingham, Kent | |||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | And thanks for the support, I'll keep you updated! Will if you dig out the pic of your lad in the car that'd be cool, I remember that well | ||
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aka chris_evz Posts: 2726 Location: brynna south wales | |||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Huge photo update incoming! I've lost the order these are supposed to go in somewhat, but you'll get the idea. Just waiting for them to upload. Long story short; -Car collected -Car assessed -Car disassembled and stripped down -Chassis to shot blaster -Chassis back from shot blaster This is where we are now. I'll let the pics tell the full story, but the chassis is quite far gone, alot further than I (or they) thought prior to shot blasting. The underside of the tunnel is somewhat doilie like We are pretty much decided on getting a replacement from VW Heritage (£1225 for brand new mexican complete chassis), just sorting the details out. We are having a bit of back and forth discussion on what to do about the suspension. The front beam is also shot, and I have kind of seen these now...[url]http://www.red9design.co.uk/type1.htm | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Car Collected:          | ||
| Paddy |
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Car Delivered / Assessed:       | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Disassembly / Further Assessment:                               | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Back from the Shot Blasters:                  | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Photo update - new chassis!
They are following the build manual for the floor drops, and it's going pretty well although I think they are finding it a bit of a pig of a job lol We (I) need to have some serious thoughts about what to do for the front end now, still not got anything ordered in. | ||
| Marv_666 |
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 '88 MG METRO 1300 Posts: 1117 Location: Dudley, Midlands | |||
| Paddy |
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Elite Veteran Posts: 837 Location: Gillingham, Kent | |||
| cerbera |
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Forum Admin & Insurance Guru Project Pride Posts: 5690 Location: Durham - North East UK | |||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | cerbera - 3/9/2013 7:52 PMAbsolutely loving the build thread on this! Good! Hopefully people will enjoy seeing something a bit different! I'm sure that like 90% of kitcars out there, I will find some piece of metro to use on the car I know some people use two metro rads for cooling when converting from air cooled to water cooled... | ||
| Marv_666 |
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'88 MG METRO 1300 Posts: 1117 Location: Dudley, Midlands | |||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | FYI - this is the photoshop with the Fiat Coupe lights:
Personally it spoils the '70'sness of it, but it would actually make additional space to mount radiators in what effectively amounts to the wheelarches - which is surprisingly common. Probably gives a better idea of the size aswell - one metro rad each side, behind the headlights. Edited by Paddy 4/9/2013 1:07 PM | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Large update time: Gear lever moved significantly backwards, invisible but linkage also shortened to suit POR15 Chassis paint going on        Various sundries painted up Rear chassis brace assembly - ummmm shiny billet          I've lost the correct order for these, so one at a time: Brake line fabrication    Including random braided hose  Side pod damage - this was damage inflicted by me unfortunately in the initial disassembly  Hydraulic lines and air ducting down the side of the body  Loom removed - imho this should go straight in the bin, it was one of my biggest bug bares with the car  Additional body to chassis mounting points, Southways have taken it upon themselves to improve on the kit design as and where they feel it is needed, and have my full support in this lol!   LOL!   General assembly: gear lever, handbrake, peddle assembly   Rear chassis reassembly  New rear shocks  | ||
| Paddy |
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Ummm - Shiny Billet Rear chassis brace assembly and gearbox brace reassembly     Wait, what?! What could I possibly want this for? Amazing what £175 will buy you though, t&t and everything lol  Ahhhhh now I see 2.5ltr 4cyl boxer and conversion to water cooling! Fun is going to be had  Gearbox cleaned up and reassembled    And that's where we are at the moment - I'll update again soonish | ||
| Marv_666 |
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'88 MG METRO 1300 Posts: 1117 Location: Dudley, Midlands | Holy sh*t!! I've seen some rusty Beetle tanks in my time, even welded some... but that goes beyond the norm!! Looks like you've put the gearbox in the wrong way round too!?! Go on... mid-mount it... you know you want to!! | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Marv_666 - 5/1/2014 6:08 AMHoly sh*t!!I've seen some rusty Beetle tanks in my time, even welded some...but that goes beyond the norm!!Looks like you've put the gearbox in the wrong way round too!?!Go on... mid-mount it... you know you want to!! That wouldn't be nearly as much fun as hanging the engine out behind the rear axle lol, it'd almost be safe Yeah I did wonder why it smelt so strongly of petrol... | ||
| Paddy |
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Small update: Started stripping the donor Legacy for as much as possible. EJ25 removed, looking remarkably clean, and placed up on engine stand for working over. We'll be removing the heads to check and replace the gaskets as a precaution, and we'll be able to tell if it's the 155 or 165bhp engine when we can see the cams.     Dash removed, we'll be trying to use as much of the instrumentation, switches and controls from the donor as we can, whilst keeping a retro 70's feel to the interior, which will be black with red highlights out of interest.  Loom removed, again we will be using as much of this as possible. With the Nova being truly rear engined then there aren't any standard straight fit looms and anything we use will need to be adapted to fit, so by using the standard Subaru loom we keep the ECU hassles etc down to a minimum.    | ||
| Marv_666 |
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'88 MG METRO 1300 Posts: 1117 Location: Dudley, Midlands | |||
| Paddy |
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Elite Veteran Posts: 837 Location: Gillingham, Kent | I have considered the fact that it's going to want to pivot around the rear axle - once built we'll see how manageable it is, wheelie bar could be added, but I'll avoid if possible | ||
| Gandi69 |
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| Expert Posts: 11052 Location: Wolverhampton | |||
| Paddy |
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Gandi69 - 24/1/2014 8:13 PMwhat kind boots are they that you have used on the shafts from the box? seem to be secured with bolts along the length of them?  Axle Boot | ||
| Gandi69 |
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| Expert Posts: 11052 Location: Wolverhampton | |||
| Marv_666 |
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'88 MG METRO 1300 Posts: 1117 Location: Dudley, Midlands | |||
| Paddy |
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Engine pull down and sump modification pics:  Reversed water manifold thing             | ||
| Paddy |
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Elite Veteran Posts: 837 Location: Gillingham, Kent | New front beam and dry fit of Red9 Coilover kit - slight modification will be required as it doesn't exactly fit Apparently they say this happens occasionally on the replacement beams as they are slightly thicker than original parts.   Edited by Paddy 27/2/2014 12:06 PM | ||
| mk5cortinaestate |
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| Paddy |
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Elite Veteran Posts: 837 Location: Gillingham, Kent | mk5cortinaestate - 28/2/2014 8:20 PMReally cool little project you've got there. Thanks | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Kennedy Engineering adapter plate, high torque starter and funky flywheel and clutch all here from the states - more shiny Few mm's ground off the gearbox cradle to facilitate fitting the adapter plate           | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | More update! Modifications to the front struts to accommodate coilovers. Welded up modified sump. Engine reassembled. Oil pickup modification. Engine dressing.                  Edited by Paddy 24/4/2014 6:23 PM | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Further engine assembly update - looking amazing        | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Anyone for a huge milestone?       | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Time to progress the Nova in ways that will make it look no different externally whatsoever.... The 'you're not meant to have that engine' corner!  So we've got a crackin' flat-4 banger from Subaru here, but what we really need is to make it run. First thing we need for that....wiring. Que fun times....  All the loom you see going into the Nova has been harvested from the Legacy donor car. there will be the odd strip here and there which has been added, but although it took a while to remove it all from the Subaru, it means the original wiring pinouts and connectors can be kept, meaning the majority of it will be compatible with Subaru wiring diagrams. Great..........as long as you can find them!!  So here's a strip of loom that used to go to the front of a Legacy going to the rear of a GRP bodied wedge with a jet-fighter c**kpit!  Original Subaru ECU mount, heavily modified (it used to have legs!)  We'd done plenty of pre-work on the engine loom, so this is a case of getting the body loom to meet with the engine loom, and then shortening/lengthening as required and keeping it all looking like ADD were a mass-manufacturer and that it came from an assembly line. Or at least, that's the target!   Insert custom designed fuel tank here  More fuseboxes and control panels find their way into the Nova. They'll be easier to get to in here....you just move the seat forwards!  So there we have it.....wiring! Never promised it'd be exciting, but it's one of the most important aspects of the build. So far, it's going very nicely too!  First thing we did last week - take a grinder to the front.............boot??  Making fibreglass dust.   And removed! Now what?  We did it for airflow, as we need to fit a radiator - something the Beetle didn't have (unless you were trying to wind up a partsman at your local factors at 4:47pm on a Friday). But there is no airflow there, which means the bottom section also needs cutting open  One radiator! We did toy with the idea of fitting the Legacy's rad, as it's obviously fit for the job. However, sadly it didn't fit. Happily, this one did, and it's from another Legacy, only not the one we used as a donor. But like it. Just not the same. Make sense?  The lower nose section will be chopped and a 'tunnel' created for the air to travel through. We will then work out how to expell the hot air, being that for a decent cooling system, you need an air around a third bigger than the entry cross-section. Hot air expands, and all that physics jazz.  Moving inside, the dash is placed back in place to allow us to mock-up some wiring looms. Got some bits missing here!  Ah, that'll be useful!  Anyone fancy some wiring? It's pretty straightforward! Really? Nobody??  Much the same as the last time I stood in this spot and took a picture, only with slightly more wires.   Making its way underneath the car now, too. This area will be hidden by the side pods once complete.  That's all for now | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Double post  Edited by Paddy 13/8/2014 8:57 AM | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Here we have a nifty little piece of kit! it's a speedo module which hooks up to the original Beetle speedo cable and converts it into an electronic signal. This is ideal for Beetles running a stand-alone ECU, as it can take a speed input. The cable would normally carry on the other side, but in our case our new speedo is electronic, not cable operated. So we'll have end of this plugged into the speedo cable, and the wire to the ECU, and then a little spindle on the other end twirling away happily catching bits of wiring loom and ingesting dirt. Great! So what we'll do is get a piece of nylon, and pop it on the lathe. Then we'll make a really odd shape, and connect it to the other end.  Ta da! it'll be buzzing its nuts off in there and nobody will be any the wiser!  Moving onwards, it's time to tackle a biggie......cooling system! Being based on Hitler's only lovechild, the Nova doesn't have a cooling system as such, not a wet one anyway! The Subaru engine has a proper cooling system, so we'll need to modify the car to suit, and that begins with drawing on the front of it!  Like so.  And then cutting that section out, like so.   Then we make a frame to sit the radiator in. We've gone for a Legacy radiator, though it's not the version from the model we broke up as we wanted one with a central top hose position.   Radiator goes on here, like this.  Make sure it all fits nicely.  Then go about fitting the new frame in the nose of the Nova, now offered up the the car.  Yup, that works! Radiator will be at a hell of an angle, so we'll need to duct the airflow into it. We could have used a smaller rad and got it more upright, but then there's a good chance it wouldn't be man enough for the 2500cc iron-blocked Boxer lump.   The cradle bolts into the nose.  Now the ducting!  Carve bits of foam up to create the shape required.  Slot them into place.   Keep going until you've done it all (takes quite a long time!)   There, all ready for lay-up in fibreglass.    It'll change the look of the front slightly, but in my eyes at least, for the better! next time we update, it should have been layered-up in GRP.  | ||
| mayoturbo |
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| Expert Posts: 2004 Location: Chepstow | |||
| Paddy |
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Elite Veteran Posts: 837 Location: Gillingham, Kent | mayoturbo - 18/9/2014 1:29 AMexcellent project! Cheers Dude And now... update! We've used the foam templates to lay some fibreglass matting down.   Kinda like wallpapering, only more itchy!  Some resin and gelcoat later....   In the meantime, we're bracing the front end. The Nova's body isn't exactly strong, and we're concerned the added weight of a big radiator full of water won't do the nosecone any good, so we're bracing it.  We decided to fashion some adjustable braces too, using rosejoints. This means once it's all finally fitted, it can be adjusted on the front end to get the panel alignment just right, as well as reducing the stress on the nosecone.  And it'll look something like this!  | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Work has continued on the cooling system. The final hoses will be new types, but for now, this is how the radiator plumbing is coming together.  Coolant hoses will pass under the chassis, conveniently nestled between the sunken floors we had to fit to the Beetle chassis.  At the rear, they branch off either side of the engine. There will be more to add on to both ends.  Well, it's not right now.....  Layout of the coolant piping, back to front  Same again, t'other way around  Clamps fabricated to stop them moving around.  | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Mmmmm, shiny...... | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Got the wheels back from the refurbishersMmmmmmm... Shiney...       Edited by Paddy 25/3/2015 10:10 AM | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | And some more gratuitous wheel photos now that revolution have kindly obliged with new centre caps (I'll, probably, stop banging on about the wheels after this, honest...)    Should be some proper progress photos coming up in the near future | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | Update time Words and images courtesy of Southways again This Nova's going to be a completely different car to drive! We decided we really weren't happy with the driving position as it was designed, not to mention the fact the steering column was fixed to a flimsy bit of GRP, so set about making a brace to both support the column, and allow it to mount very slightly higher.  This is what we came up with.  The rusty bit was the original mount.  Now the column sits about the height of that square tube, erm, higher.  With the column raised, attention turned to the dash and steering wheel. The original shirt button was something our customer was keen to get rid of, so for mock-up purposes we attached this wheel (a used spark plug to anyone who can identify it). The driving position is instantly better. It's almost as good as a Lamborghini Espada, which doesn't sound like high praise to anyone other than those who sat in the Nova previously.....  The dials are mocked up. Easy way to design the dash - print them off and stick them on until you're happy with the layout. That's when you get the drill out!  We have a new engine in the Nova, we have most of a cooling system, a heap of wiring and some uprated suspension. We even have stick-on dials! But we don't have a fuel tank....until now. Doesn't fit very well, mind....  .....Ah! Turn it round the other way!  The tank was actually a custom-designed unit, so it's bespoke for the Nova.  It includes a sump, so if our customer is ever brave enough to hurl it around corners as fast as it'll go in a straight line, fuel starvation will not be one of his worries. He'll have MASSIVE problems in many other areas, but the fuel will continue to pump even as the car exits the brick wall and is halfway up the tree.  Final lacing for some of the loom. The body will go back on soon, and not come back off!   Take a final look at it!  Looks a bit different under the nose now. That's where the rad will sit.  And it's now a car! Body back on, and going nowhere as we've now sealed it as well as bolted it. Should add strength, eliminate squeaks and creaks and keep it water-tight.  Body back on, and going nowhere as we've now sealed it as well as bolted it. Should add strength, eliminate squeaks and creaks and keep it water-tight  Bit of a gap at the rear arches though, so we'll have to plug that with something. Maybe a seatbelt mount, seeing as that rough hole in the GRP is actually where the seatbelt used to mount!  That's the upper section! Note to Nova owners.....don't crash, unless you've improved this aspect of the design. Actually no, still don't crash! We'll come up with something for this.  | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | We've been working on the nose of the Nova recently. Here's the front lower valance being fitted after we'd gone round the whole thing putting strength back into it with GRP, and filling in all the original holes along the upper lip, which used to give access to self-tappers. We're not using any of that now, we're going to do it properly with hidden bolts and nyloc nuts!  The radiator mounting frame and nose-support brace we made trial fitted after powdercoating. The powdercoaters remarks were "What part of a TVR is that then?"  The brace is needed because, frankly, there's not much strength in a Nova body, especially the nose area. As soon as we pop a radiator big enough to deal with 2500cc in there, and then fill it with coolant, something's going to give! The new brace will spread the load of this to the front of the chassis, as well as providing a way to adjust the load on the nosecone and alter the sitting position.  Meanwhile, on top of the pointy nose we needed a way of keeping the bonnet secure. The original layout was two great big old-school big pins, and they really didn't look great, so we've installed some aeroquip catches instead. The car will be staying black, so they're fairly well disguised and we figured it probably needs the additional security of these catches rather than just the lock at the bottom due to the fact a previous owner had fitted them! We can remove and smooth over the hole where the bottom lock went, as it all needs removing and refitting when it's painted.  The beast beneath the bonnet? Nope, wrong end! But here you can see where the bonnet affixes...  ....and the new battery mount we've begun to fabricate.  The open mouth (which never used to be open, you'll remember) being smoothed and fettled.  We need to fit the grille before the radiator, which means we need to get the area surrounding the mouth nice and neat, as it'll be too difficult to access it once the grille's in place. We could, of course, fit everything, get it all running, and then pull it all apart to get it painted of course!  So far, so good. I think the Nova's beginning to smile!  Sent from my Nexus 6 using Tapatalk | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | The Nova's had a good month! Most of the work in September centred around lighting. Having carried out a fair number of improvements to the alignment of the rear lighting panel (and then failing to co-ordinate enough to get pictures....DOH!) we turned our attention to the headlamps. Our customer Patrick had already expressed his dislike of the original setup the Nova had (still visible on the previous image). All of the headlamp brackets were not only rusted, they were visible! Along with the side and indicator lamps looking like they were thrown in from 10ft away, it was deemed necessary to improve this area.  To that end, a plan was hatched to fabricate some cowlings and enclose the headlamp units. The indicators will be relocated to the grille, and the sidelamps will be an LED unit positioned next to the headlamp. First things first, we needed to make the cowlings. Foam cowlings? No, this is how we made the shape initially!  Best way of designing the cowlings to encase the headlamp neatly is to actually encase the headlamp! We'll get it back out ok though.  The foam was then layed up in GRP matting before the resin was applied. The result was this!  And this! Same both sides, of course! They'll need some more strengthening on the back and some smoothing on the front, prior to paint. Then we need to engineer them to be removable, as the headlamp adjustment is carried out from the front. We've already made one of the new perspex covers (mostly to make sure the new cowlings clear them!) and have fitted all the new fixings for those, but we'll cover those more at a later date.  They've improved the look of the front end no end though!  Turns out I hadn't visited here to update for a while so it's a bonus glut of posts for my trofriends | ||
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Elite Veteran Posts: 837 Location: Gillingham, Kent | |||
