otipoiss

Hello. It has been a while. 

I am still trying to start over with this. Trial fitting the body panels, bending them right, to match and follow the lines of the car shell. Maybe I find some recent pictures later aswell. 

In the last few years I've managed to secure a set of headlight washer motors. Also a wiper arm for the left hand side, but Im missing a right hand one. 

If someone has it for sale then please let me know. 

I will continue my monologue. 

Passenger side front door came from hatchback and it doesn't fit. This means that hatchbacks have lower roofline? Funny thing is that I did measure the width of the door before even bothering to remove it, but I never ever thought that a sedan door could be taller. Very unreasonable of Opel/Vauxhall. 

Anyhow, luckily I have my donor car, and that door was ok. 

A question aswell, how much do headlight wiper motors/arms cost these days? Someone from MK2Cav Facebook group did offer me an incomplete set, but I'd hate to overpay. 

Not much to report, other than the copper piping is mostly done. Handbrake system to assemble and I think its time to remove the rotisserie after that .

Also bought a bunch of parts. 

To be honest I actually bought more of them, a whole parts car 

Its a GT Sport with 20NE engine. I dont know if it would run, I dont have the motivation or time to find out either. Interior was the main reason for buying it, but I guess it will be quite convenient to have another car to look at while putting my own car back together. 

Question. Where does the fuel return line connect to? Right now im guessing to the sender unit? The fuel vapor can goes to the filling neck? Ive got 3 connections there which i guess 2 go straight to the tank. I think Im in a need of a thorough manual for assembly

Also another problem occurred, I do not have the necessary stuff to complete handbrake system, everything that is supposed to be mounted on the rear axle is either lost or gone to scrap because of being rotten. 

Keeping this thread somewhat up to date. 

So front fenders got some treatment to the inside. Thoroughly cleaned, painted, stone chip protected, and painted again. The outside will be taken care of when they are finally fixed to the car. 

I have repainted the engine bay again and I think that more successfully this time. Ofcourse its still not show-quality but will do for me. 

I also have a question. I've gotten some suggestions over time, that I should replace my original (C20NE) camshaft with a 18E one. Is this something worth doing? Does a bare camshaft give me anything or do i need the whole head from 18E? 

This is where my english is a bit narrow. I'm not entirely sure what you  mean by holds, but I take a guess that you mean all the bolts and bits. 

All of them were sand or soda blasted and then zinc plated.

Unfortunately there are not many (2 as far as I know) companies in Estonia that do plating and the one closer to me had quadrupled its prices. I think its mainly to scare off hobbyists like me. 

Some pretty little things. 

Preparations. Had to replace 3 doors actually, the one I didnt, has been replaced in the past. So there will be no original doors :D

I'm not sure you could call mine i200 as it is not a Swiss car. The car has been sold new in Sweden instead. 

Good news, I've found better doors for the left side. From my hometown, cost me nearly nothing. Happy about those. 

Out of 4 doors 1 seems to be more or less OK. Left side doors are worse than right hand side ones. Long way to go still .

Just to show some signs of life. Made some mistakes with the filler, but hey its my first time. Will redo.

Fuel gauge sender units, are these something that are related to body/tank, or engine, or something else?

Earth terminal has rotted away on mine, I think it could be welded back, but the little pipe is the bigger problem here. I dont think these details could be bought anymore...

I dont have much to report other than I accidentally found another set of Ronal Irmschers on sale. 

The only reason I bought them was the centercaps and a special tool for them. Now i need to find replacement logos for them, mine are all hazy and cracked. Anyone knows where to source these?

Thank you for your kind words and support!  Happy new year aswell to everybody!

As seen on the pictures, the underside ( and trunk ) has been painted, to a dark grey colour. I've also drawn some circles around some holes. I dont think it would be smart to leave these like this, but cannot recall if they had something in them from the factory or not?  Ofcourse i mean only those that are just holes, not the ones meant for bolts. 

Still not sure about the boot paint scheme.It seems some parts are white, some are dark grey.  Maybe someone has a picture of how it should be done? Im currently thinking of painting the boot and underside of the car at one go, with dark grey. 

Took me 4 days  to get it all sanded and all the little rust spots removed. At least those i could see. Ive also brushed seam sealer all over the place, which made it look horrible now, but i think another layer of white will not harm anyone.

Question aswell. What colour should I paint the underside? I dont think white would be very practical, but if the underside would have been white from the factory then...

Another recommendation I got  was to do something with the sunroof drainage pipes at the front. From factory they just end at the inside of the sills. No go, I have sealed those completely, the water would have no escape from there. So maybe an attempt to shorten them, continue with softer and smaller diameter pipe/hose, and guide those to the wheel arch?

Painted and covered with stone protection. Im going to add another layer of paint on top of it, that is when im done sanding the inside of the car, and painted that with primers. 

Now whats left? Some holes here and there, the roof, and the front apron, but that can be welded on after I've finished the underside. Oh, forgot about few brackets and those welds that need over doing.  My idea is to apply all necessary coatings to the underside while the car is still on the rotisserie. Plus maybe to do the brake and fuel lines. 

Working on the boot/rear apron. Since my tools are limited to hammers and dollys, and also some bits of wood,  the result is nothing near concours quality. But the grooves there are necessary, so they had to be done somehow. 

I have also ordered new front and rear aprons, hopefully they arrive next week. 

Some sandblasted and painted bits. 

I have indeed. The doors were in when i marked sideskirt holes on the sills. 

It probably isn't 100% , thats just something i will have to live with. I just hope that the difference will be hard to notice. Final adjustment to rear axle will most likely require large hammers and violence. 

Top layer welded on. Effectively it is pretty much the same as the one under it, which was shown on previous pictures, just a tiny bit larger in every measure.

Other side needs same treatment, but axle pivot for this side needs to be done first. I don't think I'll ever be able to get these 100% correct and true...

Ah at least that wont be buggering me anymore. 

Time for some 3D CAD templates again. (Loving this expression by the Legends at Bad Obsession Motorsport)

I was told that Opel Vectra (MK3 Cavalier) shares its whole underside with MK2, so I should have been looking for those bits aswell. Right now I don't even care, seems more interesting to try and reproduce the longitudinal members myself. 

Some pictures too, winter is giving up slowly. 

I have managed to source a set of Irmscher wheels for this car. I've wanted these for a long time now and they were an absolute steal. Unfortunately i dont have centercaps, but hoping to find those aswell.