bilbomk1
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Aug 10, 2022 14:42:54 GMT
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Hi all. Thought I would join up here as the new car is much more Retro Rides style than other cars I have owned. This is my first Vauxhall, spending the majority of the last 10 years playing with MX-5s. First off here's my current Eunos Roadster. Been about 3 years of rolling restoration, and it's gone from this: ![](https://live.staticflickr.com/65535/51253808703_c579584657_c.jpg) To this: ![](https://live.staticflickr.com/65535/51887562470_2a9ee39062_c.jpg) ![](https://live.staticflickr.com/65535/51253779228_4ff206b2e2_c.jpg) It's still nowhere near concourse, but I think for 186,000 miles it's not looking too bad! Basically overhauled everything, loads of welding, full respray, ITBs, all new bushes, brakes, suspension etc. etc. It's been a ton of work! Anyway! I seem to go through dailies very quickly. I get bored of things. In the last 2 years I've had a K11, Civic, Bluebird saloon, 107, Yaris, and currently a CMAX (it was £250 and does 52mpg, don't judge me). So I've been looking into and planning something the last couple of months, and decided to go for it. The plan is proper old school 4 door, RWD, MX-5 engine, daily driver. So here it is, a 1980 Cavalier 2000 GL Automatic: ![](https://live.staticflickr.com/65535/52270342743_938b118781_c.jpg) ![](https://live.staticflickr.com/65535/52270321106_04257f7130_c.jpg) ![](https://live.staticflickr.com/65535/52270342133_6935636063_c.jpg) It's already partly stripped, but came with everything in boxes, and a ton of spares. It's pretty rusty but came with a load of repair panels and sections to weld in to about 90% of the problem areas. So lets get the rust photos out of the way: Passenger rear sill: ![](https://live.staticflickr.com/65535/52269357177_4389d63be6_c.jpg) Nearside inner wing (previous owner already started to cut it out and fix it): ![](https://live.staticflickr.com/65535/52270342528_37b030ae8b_c.jpg) Another shot of the nearside inner: ![](https://live.staticflickr.com/65535/52270589284_3bee87542a_c.jpg) Driver's footwell: ![](https://live.staticflickr.com/65535/52270589129_00421ff7cb_c.jpg) Partially repaired headlight housing/wing mount: ![](https://live.staticflickr.com/65535/52270588859_957e2a36b4_c.jpg) And one spot below A pillar: ![](https://live.staticflickr.com/65535/52270813480_00e764108c_c.jpg) There's some other bits of rust around the car, one chassis leg is a bit gone, some bits of the floor are gone in some areas, but this is the worst of it. The sills are the worst part. Small amount on front wings under where the front bumper would go. I've already got started on it, only owned it a few days and just trying to crack on and get all the rot cut out and welded up. I think I've seen just 1 of these on the road ever in person that I can recall, at least in recent years, so I'm excited to get it going again. It's been laid up since 1997! However other common rust areas are pretty good! Front strut towers and bay generally is in pretty good shape: ![](https://live.staticflickr.com/65535/52270589264_dde7f3b0ac_c.jpg) Rear arch tubs are good: ![](https://live.staticflickr.com/65535/52270320616_a050dab0fc_c.jpg) ![](https://live.staticflickr.com/65535/52270814195_cf31d79df4_c.jpg) Boot shut and door shuts are nice and clean: ![](https://live.staticflickr.com/65535/52269356797_d9a855133c_c.jpg) ![](https://live.staticflickr.com/65535/52270814140_f8e60eb531_c.jpg) Roof and pillars all look alright: ![](https://live.staticflickr.com/65535/52270813660_26b6540f43_c.jpg) ![](https://live.staticflickr.com/65535/52270319971_9d9f26419f_c.jpg) Comes with all original parts that were removed, and a ton of new spares, as well as the partially disassembled original engine: ![](https://live.staticflickr.com/65535/52270589669_5a192d74bb_c.jpg) ![](https://live.staticflickr.com/65535/52270589144_e90dda308b_c.jpg) ![](https://live.staticflickr.com/65535/52270320326_c33c1c335b_c.jpg) ![](https://live.staticflickr.com/65535/52270813855_8716371c65_c.jpg) ![](https://live.staticflickr.com/65535/52270588624_8ce13a309f_c.jpg) So a lot of work to come but it's not an absolute rotter. Rear arches look great actually which I was surprised by, and most other tricky/annoying to weld areas look clean, so that's something at least! Anyway, made some good progress on it since I got it on Sunday, on the nearside inner wing and jacking point area. Got the panel the previous owner made prepped and welded in: ![](https://live.staticflickr.com/65535/52272839213_bea4fd3382_c.jpg) Never done any plug welds before, so they didn't start off too beautiful, but got better as I went on. The panel is all done now, and no pinholes viewable from the inside, so I seam sealed the welds, primed and undersealed. ![](https://live.staticflickr.com/65535/52272818656_52af0b98ea_c.jpg) The top corner bits I have had to make separately, got one of those done now as well. Decided I may as well make use of the new jacking point repair section, and cut the old one out, as well as the rusty sill end plate: ![](https://live.staticflickr.com/65535/52271848172_ea23377c03_c.jpg) I cut the end off of the full length sill section and got it welded on: ![](https://live.staticflickr.com/65535/52271848122_19bd64d0da_c.jpg) Dressed the welds a little and got it all protected: ![](https://live.staticflickr.com/65535/52271847982_e9898b0c2c_c.jpg) The floorpan above the jacking point was rusted through in some places, which is why I decided to cut the entire floor out in that section. I kept cutting away until the new panel started to fit a bit better. It is the same shape, but some minor variations to the original. The chassis rail the jacking point attaches to is fortunately in great condition, so that won't need cutting out. I have now welded in some sheet to replace the floor section, and need to plug and seam the jacking point to it after. I will also be welding it to the sill and the chassis rail as it was from the factory. I likely won't use it to actually jack the car up, but want it to be as strong as it was designed to be. With a little more work it should fit perfectly: ![](https://live.staticflickr.com/65535/52273308945_81eebde79c_c.jpg) I buzzed back the metal in front of the door and it was all perfect, so I primed and undersealed it to keep it good: ![](https://live.staticflickr.com/65535/52273308940_bc0bca408c_c.jpg) The good thing about the car in this area is that the back of all the repairs I have welded in so far can be accessed from the other side, so I am able to properly paint and protect them when I am finished. And here is the (unfinished, horrible to weld) floor plate that I have started to weld on: ![](https://live.staticflickr.com/65535/52274398767_3a48a6fe84_c.jpg) Should have this corner all zipped up by the end of this week, and then it is on to the rear sill and removing the front subframe for overhaul.
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Last Edit: Aug 10, 2022 14:45:59 GMT by bilbomk1
1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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ems1
Club Retro Rides Member
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Bilbo's mk1 Cavalierems1
@ems1
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Aug 10, 2022 15:48:58 GMT
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Nice project you have there. Are you using the Cavalier axle or fitting one from an MX5? I look forward to seeing it completed.
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1985 Manta GT/E 16v 2001 VW T4 Caravelle
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bilbomk1
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Aug 10, 2022 16:01:45 GMT
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Nice project you have there. Are you using the Cavalier axle or fitting one from an MX5? I look forward to seeing it completed. Thanks, it's certainly going to keep me busy! At this point I want to retain the standard rear axle, fitting an entire MX-5 rear subframe would just add tons to my workload and I'm sure the standard diff will be able to handle the approx. 120whp the VVT engine will give. As long as we can line everything up I'll just get a prop specialist to make up something custom to link it to the MX-5 gearbox and we should be all good. In theory haha. It's going to take a while, just trying to get the rust repairs out the way first as it's the worst job, so grim and messy, so just want it done so I can start overhauling the old suspension/ball joints/brakes etc. Got a load of parts ordered so should make some decent progress in the next few weeks.
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1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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Aug 10, 2022 16:54:04 GMT
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No messing about there. Cracking project.
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Aug 10, 2022 21:42:20 GMT
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Nice project. I had a Mk1 Cavalier GLS Sports Hatch as my first car. Had a lot of fun with it. The back axle is not a bad setup as it came from the factory. This is the same as mine. I killed three engines in mine from over doing it a bit. So I cut my losses and sold it. But ended up buying another one a year later. It was even the same colour.
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1955 Austin A30 1981 Jawa Mustang 1990 Trabant 601 (Tommy) 1989 Trabant 601 2009 Jaguar XF 2012 Toyota AYGO 2018 Scomadi TL
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bilbomk1
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No messing about there. Cracking project. Thanks, trying to get stuck right in and get it done asap. Nice project. I had a Mk1 Cavalier GLS Sports Hatch as my first car. Had a lot of fun with it. The back axle is not a bad setup as it came from the factory. This is the same as mine. I killed three engines in mine from over doing it a bit. So I cut my losses and sold it. But ended up buying another one a year later. It was even the same colour. These seem really rare now, the ones I saw for sale commanded a premium if they were the Sports Hatch. I do really quite like the coupe versions as well, but part of me really wanted a 4 door.
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Last Edit: Aug 11, 2022 2:20:22 GMT by bilbomk1
1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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bilbomk1
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So spent this evening working on the jacking point and floor area on the nearside. Really horrible job, so many little awkward shapes to cut out and weld in. I'm no fabricator, I'm in digital marketing for a living 😂 so some things have taken me a while to get right, but getting there now. Not a great photo but I'm pretty happy with how this is going: ![](https://live.staticflickr.com/65535/52281757116_1a6d58bc46_c.jpg) I want to make it as strong as possible so I have seamed the entire new jacking point around it's edges to the floor and the chassis rail. The jacking point piece has an end plate that goes vertically up into the sill. I have welded one side of this to the inner sill and will get the other side sorted tomorrow, and I have one more seam to run on the far side of the jacking point on the underside of the chassis rail. Will have that sorted in the morning. Once this is done I'm going to plate up the big gap further forward, welding the sill lip to the inner wing I posted before. Then I'll be moving backwards onto the rear sill. It's a bit nasty! Here's a better photo showing just how sad it is: ![](https://live.staticflickr.com/65535/52280777907_9811657554_c.jpg) Mmmm, crispy 😂 It'll be mint in no time!
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1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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All I can add is “Oh My Word”
That is a big enough challenge.
The MX5 is looking lovely
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bilbomk1
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Aug 13, 2022 17:11:05 GMT
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All I can add is “Oh My Word” That is a big enough challenge. The MX5 is looking lovely It is quite a challenge, far more welding than I've ever taken on myself haha. Thanks, it's taken a long time and still plenty to do, but it's so much cleaner now than it was!
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1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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bilbomk1
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Aug 13, 2022 17:24:37 GMT
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So I got the front nearside all welded up and protected today. The shape was a bit of a ballache, but I got some pieces cut out that fitted quite nicely. ![](https://live.staticflickr.com/65535/52281910952_fb4e611433_c.jpg) I went a little overboard on the seam sealing I think haha, but I got all the welds sealed inside and out, then primed and stonechipped everything after: ![](https://live.staticflickr.com/65535/52281910882_cde4391b83_c.jpg) Looking much better now: ![](https://live.staticflickr.com/65535/52281910767_4258c0ac90_c.jpg) The passenger now has a solid floor! ![](https://live.staticflickr.com/65535/52283374875_6da452bc71_c.jpg) Also cleaned back and welded up the hole just below the A pillar: ![](https://live.staticflickr.com/65535/52281910657_cf8269e02c_c.jpg) ![](https://live.staticflickr.com/65535/52283374675_d081962c8d_c.jpg) Everything inside that area has also been cavity waxed, managed to get it all inside the new jacking point, and inside the front of the sill I have rebuilt. Pretty happy with it all so far tbh, far more major welding than anything I have ever done before. Learning quite a lot as I go, blown a fair few holes, but slowly improving!
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1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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bilbomk1
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Aug 14, 2022 23:29:30 GMT
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So no rest for the wicked. Woke up this morning with a moderate hangover, but couldn't waste the day. Got over to the unit, laid down on the floor and stared at this utter misery for about 20 minutes, debating what my plan was: ![](https://live.staticflickr.com/65535/52280777907_9811657554_c.jpg) Finally got my act together, jacked the back up, and started cutting out the rot: ![](https://live.staticflickr.com/65535/52285918843_a235b081fe_c.jpg) Put the flap disc to good use to work out what was saveable and what wasn't. I was quite surprised at how much of the metal in there was actually still good, I had been expecting that an entire cut out of everything was going to be needed: ![](https://live.staticflickr.com/65535/52286187049_af416c39e9_c.jpg) The floor was looking grim before a mid-job sweep up: ![](https://live.staticflickr.com/65535/52286178064_71033a5080_c.jpg) You can see a couple of points on the inner sill that were gone on the photo above, just to the left of the jacking point. I got those cut out and new patches welded in, as well as rebuilding the end section (which looks a little curse word in this photo, my Cardboard Aided Design wasn't 100% up to scratch today! I soon cut it nice and level with the rest of the inner sill line): ![](https://live.staticflickr.com/65535/52286400610_4e723b6219_c.jpg) Anyway, with the holes dealt with and the end piece re-done, I got to work with my full sill panel to redo everything else. I was quite happy that the area surrounding the passenger seatbelt captive nut was all great and strong, and the area around the jacking point felt good. Gave it some grief with a screwdriver and the flap disc but no more holes to be found, which is good. So I got the rest of the sill rebuilt and got the outer welded on. Fair bit of grinding was needed to get the joins looking presentable, but I'm very happy with the result. It's on there, it fitted well enough, and I stuck an LED light in the end plate and there were no visible pinholes, so I got the welds seam sealed up. ![](https://live.staticflickr.com/65535/52284933717_29158a9b47_c.jpg) ![](https://live.staticflickr.com/65535/52285912506_197744f4ac_c.jpg) Overall fairly happy with how it has come out. I need to address a couple of bits down on the sill lip, a couple of the plugs went a bit ugly, and then it's just a case of welding on an end plate in front of the rear tyre and this sill is done! Couple more little holes in the floor to deal with on this side, but only 7 days in and I'm thinking I should have all the welding done in the next week or so, and then on to refurbing the front subframe!
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Last Edit: Aug 14, 2022 23:40:54 GMT by bilbomk1
1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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bilbomk1
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So no major update as I begrudgingly took a day off the car yesterday to do some food shopping haha, but I have ordered a ton of stuff to refresh the underneath. I haven't even really inspected most of it, but it's been off the road 25 years so I thought it could probably do with it all being done. So far I've ordered:
Upper ball joints Lower ball joints Inner tie rods Track rod ends Front shocks Lowering springs (40mm) Rear brake cylinders Brake drum rebuild kit Rear shoes Front pads Dinitrol 1000 cavity wax (I like this stuff, used it to good effect on the 5 when the rust was sorted)
Need to order a few more bits: rear shocks, front caliper rebuild kit, and probably all the bushes tbh, still looking into options for the bushes as don't really want savage poly ones but rubber ones seem basically non-existent from my initial searches.
Other stuff I'll just buy as and when I get to it, but it will be nice to refresh all the old bits before ever driving it. I'll be back on the welding this evening!
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1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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bilbomk1
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Aug 16, 2022 23:53:58 GMT
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Small update this evening. I got the sill end in the arch well cleaned up for welding. Grabbed an extra long 360 degree cavity wax nozzle from an old can of Dinitrol and it fitted perfectly onto my can of zinc primer, so I stuck that deep into the sill and gave everything another decent coat of primer, completely covering all the welds I have done from the inside. Then I got on with welding a new sill end plate on, which went pretty well I think: ![](https://live.staticflickr.com/65535/52291366775_95109d774d_c.jpg) Got everything tidied and seam sealed up: ![](https://live.staticflickr.com/65535/52290879363_8950d85ea1_c.jpg) I'm going to holesaw a small hole in the sill end plate, just like it had OEM, this will allow me to properly spray cavity wax into the sill, and also can be used in the future as an inspection hole to monitor any corrosion. After having some minor issues with welding and cavity wax being present in the past (fire, very quickly there was fire 😂)I thought I'd leave that bit until the welding was done. Once done I'll get an appropriate sized rubber bung to fill the inspection hole. Really happy with how this is going. One more floor hole to deal with near to the front on this side, and then it's on to the other side. Stuck my index finger through the rear of the driver's side rear sill this evening, it looks a little sad in there, but nowhere near as bad as this side was, so it'll be light work.
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Last Edit: Aug 16, 2022 23:59:55 GMT by bilbomk1
1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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ChrisT
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Bilbo's mk1 CavalierChrisT
@christ
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Loving your MX5 and this looks like a great project with some nice repair work going on.
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bilbomk1
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Aug 17, 2022 12:31:28 GMT
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Loving your MX5 and this looks like a great project with some nice repair work going on. Thanks mate! The 5 is great but is taking a bit of a backseat at the moment, just got a fresh MOT on it, got a list of things I want to sort out, but it needs to wait haha. Still runs nice enough, but the stem seals are getting very sad now near the limiter haha. Yeah I've really thrown myself in the deep end with this one for sure! Lots of things to consider with an engine swap plan like this. It'll get done, just figuring out wiring plan, adding a clutch pedal, brake booster being in the way of intake manifold etc. None of which I have ever had to do before, but I have a welder and a hammer, so it'll work whether it wants to or not haha. My mate has just acquired a mk2.5 MX-5 that is heading for scrap. It still runs so I'm having the 1.8 VVT engine and entire wiring loom out of it for cheap, so that's one thing sorted at least.
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Last Edit: Aug 17, 2022 12:32:32 GMT by bilbomk1
1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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bilbomk1
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A couple of bits of floor patched up this evening, all went quite well: ![](https://live.staticflickr.com/65535/52293308259_6a343cf6f6_c.jpg) ![](https://live.staticflickr.com/65535/52293308244_5a8f73940d_c.jpg) The grotty looking bits under the second photo aren't rust, it's that nasty insulation stuff you have to chisel to get off. Horrible stuff so I just chiseled off enough to do the repair without melting/setting fire to the rest. The minor orange patches to the right are only superficial and I'll get them buzzed back soon. A bit of chassis rail underneath the repair in the second photo appears to be gone too, so I've added it to the list of bits to sort. Left side is now all done, and I've cavity waxed the sill and all inside the rear arch tubs (which are absolutely mint!).
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Last Edit: Aug 18, 2022 0:14:06 GMT by bilbomk1
1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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ChrisT
Club Retro Rides Member
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Bilbo's mk1 CavalierChrisT
@christ
Club Retro Rides Member 225
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Yeah I've really thrown myself in the deep end with this one for sure! Lots of things to consider with an engine swap plan like this. It'll get done, just figuring out wiring plan, adding a clutch pedal, brake booster being in the way of intake manifold etc. I'm sure you've done your research so probably know this already but IIRC a Mk2 VW Polo servo is a direct swap and is a bit smaller than the standard one, or just do away with it and fit the master cylinder straight to the bulkhead as I've done to clear the twin carbs on my XE. It is possible to adapt a standard pedal box so it actuates a clutch master cylinder located next to the accelerator cable, as if the brake servo is going to be in the way a clutch cylinder will also be. Probably be easier to convert the MX5 'box to cable.... None of which I have ever had to do before, but I have a welder and a hammer, so it'll work whether it wants to or not haha. Excellent approach ![:D](//storage.proboards.com/forum/images/smiley/grin.png)
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bilbomk1
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Yeah I've really thrown myself in the deep end with this one for sure! Lots of things to consider with an engine swap plan like this. It'll get done, just figuring out wiring plan, adding a clutch pedal, brake booster being in the way of intake manifold etc. I'm sure you've done your research so probably know this already but IIRC a Mk2 VW Polo servo is a direct swap and is a bit smaller than the standard one, or just do away with it and fit the master cylinder straight to the bulkhead as I've done to clear the twin carbs on my XE. It is possible to adapt a standard pedal box so it actuates a clutch master cylinder located next to the accelerator cable, as if the brake servo is going to be in the way a clutch cylinder will also be. Probably be easier to convert the MX5 'box to cable.... None of which I have ever had to do before, but I have a welder and a hammer, so it'll work whether it wants to or not haha. Excellent approach ![:D](//storage.proboards.com/forum/images/smiley/grin.png) I did see a Polo booster mentioned actually when I was searching up removing the booster entirely, but didn't look into it more. Good tip, thanks. My mate is picking up the MX-5 this eve so will probably pull the engine out of it tomorrow night, and we'll lower it in with the box attached and see what we're working with. Praying it fits in the tunnel haha! Another fun point is that this car was an automatic, so I'm going to need to fit an entirely new clutch pedal anyway. I have seen some aftermarket pedals available with the master and reservoir located within the car itself rather than the bay, which may be a good option, and just get a custom braided line made to link it to the MX-5 slave. But your idea of having the actuated pedal is good, as there is room over to the right if needed. As for booster removal, I have been thinking I could just fit a slightly smaller master than OE one, and fit it higher on the pedal to reduce effort required for breaking. Probably won't feel OEM, but it should make it a little less rock hard. I've also got some new front stabiliser links ordered, and some rear shocks (the rear is so soft right now it is hilarious, I think the shocks have given up completely).
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1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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bilbomk1
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So gave myself a break from the welding for a day and made a start stripping the front end down. Everything was pretty crusty, but it was mainly really thick cracked old underseal mixed with surface corrosion on everything, looked far worse than it was. I'm used to MX-5s so no stranger to annoying seized nuts and bolts, had some truly awful experiences with that in the past. I was really surprised that some of the most horrendous corroded nuts actually came undone on this. Even the tiny 10mm bolts on the super rusty brake dust shield came off with no problems. Of course some stuff needed cutting off, the stabiliser links are a sleeve design with big washers either end and a bolt through the middle. Time had not been kind to it, so that needed an angle grinder, as did the bolts on the upper ball joint. Lower ball joint took some blow torching and some big old lump hammer swings, but eventually popped out. Didn't get before photos of the passenger side, so here is the driver's side: ![](https://live.staticflickr.com/65535/52296465752_05350b3fa7_c.jpg) The side I have done tonight looked much worse than this. Being the nearside I suppose that makes sense, usually seems to be the case. A ton of grime, underseal, bits of flaky surface rust, and chopped off parts covered the floor, it was rank: ![](https://live.staticflickr.com/65535/52297718504_c61a4885c1_c.jpg) With everything removed from them I gave the arms/hub/dust shield, and everything on this side of the car a really good wire brushing, and then a decent coat of Bilt Hamber Hydrate80. I've used this stuff for years, it's a great rust converter for surface rusted parts. ![](https://live.staticflickr.com/65535/52297947230_e9d9872ca8_c.jpg) ![](https://live.staticflickr.com/65535/52297457593_f8957aa97b_c.jpg) Goes on lilac, this was after about 10 or 15 minutes ish. I'm leaving it overnight to do it's thing, they will be far more black in the morning. The I will prime and paint and get them prepped to go back onto the car. All my stuff has arrived now, so I should be able to get this side finished tomorrow morning. My mate has just picked up a mk2.5 MX-5 breaker as well. Ideal timing, I am having the engine, entire loom, and various other parts off of it. It's already at the workshop, and still runs, so will check the other engine out tomorrow and pull it out. Really excited now, it's all coming together.
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1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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bilbomk1
Part of things
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Aug 21, 2022 23:52:35 GMT
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So, got some more bits done this weekend. Put together the front left with all the new parts, which is pretty satisfying. All the parts so far have fitted, which is great. The eye on the lower shock mount was marginally thinner than the original, but with a couple of spacer washers on each side it all went on fine. ![](https://live.staticflickr.com/65535/52298012452_8805926d0a_c.jpg) ![](https://live.staticflickr.com/65535/52299262749_f78c523800_c.jpg) New ball joints went in nicely and the lower felt like it pressed in tightly with our 12 ton press we have at the workshop. Annoyingly I ran out of underseal spray, so I need to finish a couple of bits off. Also overlooked ordering wheel bearings, the ones I took off inside the hub were perfectly sealed behind the cover cap, and looked brand new. But it's been sat for an awfully long time, and while they seem to spin fine, for the sake of £10 or so per side I may as well replace them. Overall pretty happy with how the refresh is going on this side, though I won't know if these lowering springs sit nicely until we have the engine in. Speaking of the engine, here it is: ![](https://live.staticflickr.com/65535/52302036211_4d28eeda7f_c.jpg) 1.8 VVT engine out of a mk2.5 MX-5. 86k miles on the clock, it started and ran fine when I moved it into the unit this afternoon. Good stuff. So I started stripping the loom off first. The engine side is easy, just unplug everything. But removing an entire MX-5 loom out of the car I have never done before, and my god I don't want to ever have to do this again. It's not horrendous, just very laborious, and literally everything has to be removed for you to get to it all. ![](https://live.staticflickr.com/65535/52302048853_3fbe662346_c.jpg) This was the scene earlier. Got the dash out and started feeding everything out of the bay through the holes in the firewall. Tedious work but the main loom is now completely removed, and fully intact (well apart from the ABS plug wiring which was being a pain and I don't need it, so I just lopped it off completely). I have added named sticky notes to various plugs and sensors to help me make sense of the loom when fitting it into the Vauxhall. There will be a load of this loom I don't need. Various features won't be required, off the top of my head things like central locking, electric windows, ABS, airbags and seatbelt sensors will be removed where necessary. I'll have a sit down with a full wiring diagram and see how much of this loom can be taken apart, as there's no point installing things that won't be needed. But I decided to take it out whole so that I didn't accidentally chop something off I actually needed! I'll get the rear part of the loom out of the car tomorrow, which mainly comprises just of rear light related items, fuel pump stuff, and the main battery terminals. I am planning to run the battery in the boot of the Cavalier, so the MX-5 loom is ideal, it'll just need extending a bit due to the longer car it is going into. Should also hopefully have the engine out tomorrow as well. 2 weeks in to the project today and it's going pretty well I think!
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Last Edit: Aug 22, 2022 0:04:22 GMT by bilbomk1
1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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