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THE EH
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#181 Posted : Monday, 5 May 2014 2:10:17 AM(UTC)
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Bugger, broke off one of my custom made timing cover/water pump bolts. Not a huge deal just another hour or so pulling everything apart and remaking another bolt..
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#182 Posted : Sunday, 11 May 2014 2:42:09 AM(UTC)
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Extractors out so I can remake the steering column and intermediate shaft as well as a new set of bigger tube extractors.
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#183 Posted : Friday, 16 May 2014 6:21:11 PM(UTC)
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TS Astra power steering pump. This is my solution. Cheaper and quicker than a mechanical pump.



High pressure hose fitting couldn't be simpler. This fitting from Pirtek bolts straight on and gives me a #6 AN fitting. Too easy.
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#184 Posted : Saturday, 17 May 2014 2:46:10 AM(UTC)
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Header plates and stub pipes ready to go for new 1-3/4" headers.




1-3/4" 180 degree bends will form the basics of the primary pipes for the Tri-Y style headers.
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#185 Posted : Monday, 19 May 2014 4:34:03 AM(UTC)
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New steering shaft in place. There is more space than with the old Torana rack setup. The rear pipe will turn forward before turning down. This will allow me to keep the same radius bends on all 8 cylinders.
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#186 Posted : Monday, 19 May 2014 4:35:50 AM(UTC)
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Old steering column out.



A qucik comparison to see how close the new column is. The steering shaft itself will need to be extended about 50mm. This is easy and there is heaps of overlap between the upper and lower shafts.



Completed new column next tothe old one. I still need the billet lower column mount to arrive from the US before I can press everything together.
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#187 Posted : Friday, 23 May 2014 6:44:08 AM(UTC)
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Lower column mount arrived from the US. It was machined to match my column




Lower mount and lower column pieces. These will be pressed together




No press in the garage so a big G Clamp, some lube and away we go.





Lower half of the column complete




Column trial fit






Column nearly finished. I still need to access a press to press the steel Commodore upper column to the aluminium intermediate column section..




This is the engine bay end of the column..
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#188 Posted : Sunday, 1 June 2014 4:38:52 AM(UTC)
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Extractor pipes ready to go. Just need to stick it all together.
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#189 Posted : Sunday, 1 June 2014 4:53:28 AM(UTC)
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Main 80 amp fuse carrier for the Astra Power Steering pump,



TS Astra power steering pump mount.




ower steering pump utilises factory mounting bolt positions and retains the Astra pump insulators to keep noise down.







This is what it looks like under the guard. It's quite well hidden and will only need a simple cover to keep the road grime and water off it.
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#190 Posted : Monday, 2 June 2014 3:49:27 AM(UTC)
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Finished pump installed. All that's needed is the switching wiring and the pressure hose connection..










Power steering pressure hose end fitting installed. I have never worked with this teflon type hose before. It's fiddly to get the braiding flared out and the olive inserted but still quite straightforward..Other end may have to be a 45degree so I'll wait until the final install before I assemble the other end..
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#191 Posted : Wednesday, 4 June 2014 2:00:27 AM(UTC)
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Speedflow braided pressure hose in place. I covered it in Speedflow black sleeve to hide the hose and protect it.



Pressure and return line fittings modified and ready to be fitted.
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#192 Posted : Sunday, 8 June 2014 6:40:38 AM(UTC)
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Driver side upper pipes done. Lower section will be done off the car on a spare motor.



Passenger side upper pipes done. Lower section will be done off the car on a spare motor.




All upper pipes done and removed ready to go on the spare motor. This means I can sit comfortably and make up the lower sections




Collectors in position so all I need to do now is get all the pipes down to the collector and keep everyone as close as possible to 36" long.





Basic pipe work sorted out. I will need to tweak number 7 pipe a bit as I need to add the most length to it. No big deal though




Basic pipe work sorted out. I need to remove the knock sensor off this motor before I can work number 6 pipe out. THE EH doesn't use one so I don't need to worry out clearing it with that pipe..
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#193 Posted : Friday, 13 June 2014 7:17:00 AM(UTC)
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Wheel stud holes needed to be gently persuaded from Commodore PCD 120mm to HQ PCD 120.65. This was done slowly and steadily with a 6mm twin flute milling bit in the die grinder. Fit is now perfect..




About 3mm clearance between the rim and the caliper.




Mocking up caliper mounting brackets




Wheel tucks up in the guard neatly. Looks like I got the offset of the wheels right.
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#194 Posted : Friday, 13 June 2014 7:21:43 AM(UTC)
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Trial fit of plug leads to ensure they clear the new pipes.







This is exactly the look I was going for. Nice and clean with just one neat weld on each pipe
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#195 Posted : Monday, 16 June 2014 5:14:48 PM(UTC)
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New and improved front crossmember outrigger ready to be welded to the crossmember. I love the new design from Southern Chassis Works.






Caliper brackets in place. The bracket is a full circle bracket so I can rotate it to get the best clearance. Then I just need to drill the bracket in bolt it on.
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#196 Posted : Sunday, 22 June 2014 4:42:58 AM(UTC)
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Front end painted and ready to be reassembled.
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#197 Posted : Monday, 23 June 2014 6:46:33 AM(UTC)
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Front end installed but not yet finished.
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#198 Posted : Tuesday, 24 June 2014 5:27:02 PM(UTC)
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#199 Posted : Sunday, 29 June 2014 7:24:24 AM(UTC)
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Front lower control arm bolt covers fitted. These neaten things nicely
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#200 Posted : Sunday, 29 June 2014 7:27:56 AM(UTC)
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Yet another job to get finished is the collectors on my extractors. I have never been happy with how low the exhaust hung below the car. The solution I have is to more rigidly mount the entire exhaust under the car. I can mount it up higher and hopefully not have issues. However I need to allow for movement of the engine. These flex pipes should allow that. The V band connectors are more compact than 3 bolt collectors so should also help with clearance..





I needed some gaskets for my new headers so I made them. Cheaper.
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