Northcape turbo project

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Northcape turbo project

by James_Mould » Sat Jun 13, 2015 9:05 pm

Right I've finally got round to uploading pictures to my laptop and thought it was time I created a project thread.

So here she is the day I got it home.
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A bit of history about the car: Its a 1996 4x4 turbo in Northcape. Its done 71000 miles. Its had 2 previous owners, the first one until 2013. It has full service history. It had a new engine fitted buy Vauxhall in 1999 at 32,000 miles. The paper work/ receipts for this work say exchange of unit due to faulty engine. I'm not sure what fault was or how it happened so its a good job the original owner purchased an extended warranty. So essentially the engine has only done 39,000 miles. It has also been completely cleaned up underneath and under sealed in 2012. Unusually this car came with a cloth interior.

As with any Calibra there are a few small issues that need to be addressed. There is a couple of small rust patches on bottom of drivers door and on drivers side sill. The rear bumper is marked where a towbar had been fitted. These will be sorted out when it goes to the bodyshop. There was an oil leak coming from the sump gasket. Apart from that the car is in really good solid condition.

Fist job was to give the car a good clean inside, out and clean up the engine bay. Few little jobs done, removed and cleaned out screen washer bottle and new Vauxhall battery fitted as drop test showed old battery to be in poor state of health. Oil sump gasket replaced with gasket/ baffle plate and stainless sump bolts fitted.

I decided to fit one of the leather interiors I had as I prefer a leather interior to a cloth one. Made a good set out of the two I had.
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A few bits collected while I had my old black turbo and few new bits to fit, but the list keeps getting longer with things I want to do.
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I've had a set of angel eyes in the shed for years and the passenger side one was faulty, so I decided to use the clear lenses and fit them to the standard headlights. so I removed the clear lensed and binned what was left of the angel eyes. Removed the glass from the standard headlights and fitted the clear ones.
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after some cleaning of the standard headlight units and some PlastRX on the plastic clear lenses.
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Headlights fitted to car and new heat shield fitted.
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While I had the bumper off I fount the brackets that hold the corner splitters to the front bumper had completely rusted through so Ive made some new ones out of 2mm stainless so the won't rust again. Also managed to get some new (old stock) corner splitters from Germany.
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Scorpion stainless cat to back exhaust fitted.
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Home made stainless de-cat pipe fitted. Sorry for the poor picture but I forgot to take a picture before I fitted it.
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This is the engine bay as it stands. Strut tops painted white. 3" stainless AFM to turbo pipe fitted. Painted spark plug cover. Rocker and cam belt covers will be painted northcape when car goes to bodyshop.
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Re: Northcape turbo project

by James_Mould » Sat Jun 13, 2015 9:14 pm

So recently as mentioned in another post I'm having fuel/ electrical issues which seemed to start on Thursday when I went to take the cally for a run. The fuel pump will not prime but works fine when the relay is shorted out. I've fitted a known working relay I can get the car to start when the relay pins are shorted and the pump runs fine when the car is running. So a bit of investigating is required.
Also when running under heavy load the car felt like it was being starved of fuel. After doing some investigation and dropping the fuel tank I found the plate that houses the fuel pump and fuel lines to be corroded. The Fuel feed pipe elbow is loose in the plate.
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I will be making one out of stainless and while I've got the tank off I will fit a Walbro HP pump and run all new rubber fuel line on the rear of the car.
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Re: Northcape turbo project

by Allys Cally » Sat Jun 13, 2015 9:49 pm

good work mate, be nice to see this one at Billing this year :wink:
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Re: Northcape turbo project

by rich30mex » Sat Jun 13, 2015 10:28 pm

Looks great mate well done pal
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Re: Northcape turbo project

by craigyboy » Sat Jun 13, 2015 10:40 pm

Nice work James,see you in a couple of weeks :handgestures-thumbup:
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Re: Northcape turbo project

by RedCalibra33 » Sat Jun 13, 2015 11:25 pm

Is this meguiars plastrx any good?
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Re: Northcape turbo project

by v6 steve » Sun Jun 14, 2015 8:47 am

looking good mate roll on Billing 2015
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Re: Northcape turbo project

by James_Mould » Sun Jun 14, 2015 8:07 pm

RedCalibra33 wrote:Is this meguiars plastrx any good?

Yes its really good stuff. Works well on acrylic type plastics too. Althought if your headlights are really bad you will be best off using wet and dry first, then use the PlastRX to finish them off.

I agree it the white doesn't look quite right at moment but will look good agains the rocker cover when its painted northcape.
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Re: Northcape turbo project

by Callyscot » Sun Jun 14, 2015 11:06 pm

Good work :clap: hope to see you at Billing.
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Re: Northcape turbo project

by James_Mould » Fri Jun 19, 2015 10:36 pm

Today I've been busy trying to sort fuel issue out. I found a break in the signal/ ECU wire. This has solved the problem with power/ priming of the fuel pump when ignition is turned on.

I have made a new fuel tank cap out of stainless steel. The ring is made from 1.5mm and top plate made from 2mm, with 10mm dia fuel connectors on the bottom and 8mm ones on the top.
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All fitted and new fuel lines attached.
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I have also fitted a Walbro HP 255lph fuel pump while the tank was off.

Fuel tank straps have been cleaned up and new m6 studs welded on so I can fit the wheel well cover.
Before
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After
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I've made a fuel tank heat shield. Its only a prototype made from some 1.5mm stainless. The old one is so corroded and had broken away from the mounts I couldn't measure it accurately. It fits so I will make an exact copy from 1mm stainless when I get some in at work.
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Re: Northcape turbo project

by Mark1 » Sat Jun 20, 2015 6:04 am

That's coming along nice
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Re: Northcape turbo project

by rich30mex » Sat Jun 20, 2015 7:26 am

Nice work pal don't suppose you fancy making another fuel tankcap do you :D
It's looking great pal
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Re: Northcape turbo project

by Phill » Sat Jun 20, 2015 9:52 am


I can see quite a few similar requests appearing


And another heat shield ?
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Re: Northcape turbo project

by sealeysonic » Sat Jun 20, 2015 11:24 am

very interesting......great work there......Question....how many wires are going to the pump...?
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Re: Northcape turbo project

by wuffy » Sat Jun 20, 2015 12:32 pm

Good work on the Turbo, id be interested in a fuel tank top plate too. :D
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