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Thread: Giles's Nova

  1. #11
    Senior Member bushboy's Avatar
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    Re: Giles's Nova

    And the good thing about the JAP spec steering column is that the indicator switch is on the correct side of the steering wheel. Now that we have got rid of the AUDI & the family car is a Mazda & the reek has a Mazda column there is no more putting on the wipers to go around a corner.

    bushboy
    "Always do what you are afraid to do"
    "I can accept failure, but I can't accept not trying"

  2. #12

    Re: Giles's Nova

    Oh yes, scares people to death when you go to squirt the screen but end up giving a loud long blast on the horm for no reason Thats the reason I put a different column in as well, the more on the column, the more room around the dash area.
    Follow my Avante Build - Target = Stoneleigh 2012 Definitely!!

  3. #13
    Senior Member
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    Re: Giles's Nova

    And the good thing about the JAP spec steering column is that the indicator switch is on the correct side of the steering wheel. Now that we have got rid of the AUDI & the family car is a Mazda & the reek has a Mazda column there is no more putting on the wipers to go around a corner.
    My daily car is an Audi A4 so if I still have it when the Nova is finished then I'm very likely to wipe the windscreen or blast the horn instead of indicating!

  4. #14
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    Re: Giles's Nova

    OTHER THINGS

    Top organisation in this garage...







    JOB 9
    Engine Ancilleries


    With some of the big jobs awaiting parts, I had a hunt around the garage for small essential jobs that needed doing. I found the adaptor plate in a box which allows the Alfa engine to be attached to the VW gearbox. I used it on the Nova between '97 and '00. Usually I'm pretty good at these things but it was obvious that I'd forgotten to wire brush the bolt threads and smear them with some copper grease as they looked almost non-usable. Rust had taken over. Luckily with the dremel (always a life saver) with spinning wire brush attachment, lots of turning backwards and forwards with a nut and spanner and liberal amounts of copper grease I got them looking like new with the nut spinning up and down each bolt. This now saves us a lot of time and hassle when we come put the new engine in.


  5. #15
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    Re: Giles's Nova

    Haha those bags look like mine, i had several bags progressively getting worse in description, "dashboard"..... "dashboard thingy"....... "god knows what"
    Eagle SS - VW MK2 Economy - Body No.7

  6. #16
    Senior Member
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    Re: Giles's Nova

    JOB 10
    Heater


    In 1999, after trying out two other heater concepts which were not adequate, I made a heater which worked really well.

    It consisted of a hand made aluminium box with a heater matrix inside and holes and flanges on the box for ducting to the windscreen, face and feet. Attached to this, bringing outside air in from the front beam/steering area was a Ford Sierra 3 speed blower. Hot water flowed through water hose and soldered copper pipe from the engine, into the rear wheelarch, along the passenger side sill, into the passenger footwell, circulated the matrix and back to the engine. A brass shut off valve controlled the hot water so when open the hot water would circulate the matrix and when off the matrix stayed cool. This worked well for hot air or current air temp control.

    The box was very strong and the ducting hose-clipped firmly onto the admittedly rather basic plastic outlet flanges.

    Three weeks ago it looked like this:






    When I made the box all those years ago I used Gripfill to bond the aluminium panels together and to air-seal the blower where it bolts to the box. I also used it to bond on the plastic flanges. Unfortunately I used the wrong stuff. Little was I to know that in this time Gripfill would crack and break off by hand.

    So three weeks ago I decided to remove the heater box and blower so that I could remove all the gripfill and do all the bonding and sealing properly this time with some black sikalflex type sealant I bought from Car Builder Solutions. I've used it before and it's brilliant. I also decided to take the opportunity to get rid of the 'plumbers merchant' flanges for the face vent hoses and replace them with proper flanges. No expense spared this time round.

    I remember the last time I used the heater that it started to squeak and sounded like it was on its last legs. So, I was prepared to have to buy a new blower. I certainly did not expect to find this...






    A MOUSE HOME!!!

    The mouse obviously had a perfect santuary to get away from predators and also had a gerbil wheel to play with! Unbelievable. As you can see, its 'bed' was made from feathers and sycamore leaves. Ahh, how sweet. Now where is the critter!

    When I connected the blower to the battery it sounded awful so I decided to throw it away and get a new one. But first I took off an important aluminium panel which is part of the box construction. Here is that panel in situ:




    I was lucky to find a company on eBay that specialises in breaking Sierras for kit cars and bought the same blower for about £18.

    While I waited for delivery we cleaned up the heater box of general muck and all the crappy gripfill. I then made a new aluminium panel designed for the new flanges I had ordered for attaching the duct hose to the face vents...







    ...Looking much better.


    Next I sealed all the gaps with the black sealant:







    You can see from the two photos directly above that I had to make an angled panel to divert the air coming in from the right side of the blower onto the matrix. This is because the matrix is quite a bit smaller in length than the blower motor.


    The new blower arrived so I checked it worked, which it did perfectly, cut off the side brackets and cleaned it up, taking care not to 'clean' the lubricated motor parts, and attached the bottom aluminium panel:








    The blower was then ready to attach to the heater box with small set screws (bolts to you and I) on each corner and then more sealant was used seal the gaps:




    Finally, or so I thought, I masked up various parts of the whole assembly and spray painted the aluminium panels on the box with a special black paint, really just to make it look better as the panels had permanent marker scribbles all over it...








    At this stage I thought it was finished, but it wasn't.

    The whole heater assembly attaches to the floorpan centre tunnel with two brackets, which can be seen on the photos. The right side of the blower sits pretty much level with the right tunnel side, but on the left tunnel side the blower hangs over it, well into the passenger footwell. This is deliberate so that I can still use the clutch! The passenger gets a bit less legroom but there's still easily enough. More than a Ferrari 308 anyway. Despite this 'well over to the left' position we had a problem...

    To cut a long story short, the Mark 4 dashboard, which I will be writing about soon, needs a lot of modifying to get various things to fit - one being the stereo (at least where I was positioning it). Basically there wasn't enough room behind the dash and the back of the stereo pushed up against the right hand windscreen vent flange and its hose. It's extremely tight back there, which is fine but not when it's too tight to be able to fit something. We just couldn't push the stereo back enough. It was an inch away from being perfect.

    After a hell of a lot of head scratching and trying a few things we decided that the best option was to remove the right hand windscreen vent flange from the top right of the heater box and re-position it on the right vertical side of the heater box, above and forwards of the foot outlet.

    We checked that it cleared my clutch foot and there was ample room and we considered the airflow speed and decided that it would be the same as the left windscreen vent.

    Here it is, slightly modified:



    Job done. Thank God for that!

    To be continued...

  7. #17
    ***Euro-Nova Supporter*** Spacenut's Avatar
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    Re: Giles's Nova

    Well done Giles - looks really good. That Mk4 dash is very, very shallow; there's barely room for the instrument backs, and of course it was never desinged to conceal a water-cooled heater matrix!

    Lauren
    only Pythagoras can save me now!

  8. #18

    Re: Giles's Nova

    When I had to lift the steering column up a bit due to legs being a tad too long, i found there is no room for the speedo which was tight anyway. So now it is sticking up by anout 1" until I get round to making a new front, when i hope it will live in the middle of the dash at the top or middle. With only the smaller guages more spread out at the back of the wheel, but life and children are making it difficult to do anything lately.
    http://jimsnova.page.tl/
    Club Nova / avante membership 031

  9. #19
    Senior Member
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    Re: Giles's Nova

    I'm sure you will both be very interested to see my dashboard post, which is coming next. We've been working on it on and off for three weeks. It's been a long challenge to say the least and I'm sure that half the time has been staring at it and thinking, but the good news is that it's looking good and it works.

    Giles.

  10. #20
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    Re: Giles's Nova

    Certainly going at it guns blazing!! And are you're sure you aren't OCD?

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