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the joys of toughened glass, you will be finding bits of that keep appearing from nowhere for years to come, one tip, before the new screen goes in go over the demist vents with a vacuum cleaner, there will probably be glass lodged in them.
screen surround doesen't look too bad and any repairs don't have to look perfect, use some non setting sealer after you put it in to keep the moisture out, I've used arbomast in the past seems OK.
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spacekadett
Part of things
F*cking take that Hans Brrix!!
Posts: 838
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the joys of toughened glass, you will be finding bits of that keep appearing from nowhere for years to come, one tip, before the new screen goes in go over the demist vents with a vacuum cleaner, there will probably be glass lodged in them. screen surround doesen't look too bad and any repairs don't have to look perfect, use some non setting sealer after you put it in to keep the moisture out, I've used arbomast in the past seems OK. I agree ☝️. I never had a screen go in my Kadett, but I know it had one at some point because every time I’ve taken the interior apart ( which is a few 😂), no matter how many times I’ve cleaned it, I always find one or two bits of glass! I will also say Arbomast is good stuff. Used it for the glass in the 100E and it was night and day better than the cheapo stuff I originally used. |
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Mechanic's rule #1... If the car works, anything left on the floor after you finished wasn't needed in the first place  |
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the joys of toughened glass, you will be finding bits of that keep appearing from nowhere for years to come, one tip, before the new screen goes in go over the demist vents with a vacuum cleaner, there will probably be glass lodged in them. screen surround doesen't look too bad and any repairs don't have to look perfect, use some non setting sealer after you put it in to keep the moisture out, I've used arbomast in the past seems OK. I agree ☝️. I never had a screen go in my Kadett, but I know it had one at some point because every time I’ve taken the interior apart ( which is a few 😂), no matter how many times I’ve cleaned it, I always find one or two bits of glass! I will also say Arbomast is good stuff. Used it for the glass in the 100E and it was night and day better than the cheapo stuff I originally used. Yes, already finding bits of glass appearing every time I shut the door already haha. And good point on the non-sealing sealant, I am getting some 3M Windscreen stuff which is the exact type you describe. |
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1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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So, what a crappy weekend that was 😂 However I have been chipping about in my girlfriend's Alto, I do quite like the 50+ MPG I won't lie 😂 So I turned my attention to the windscreen aperture. A few holes, but in terms of the actual rubber mounting lip, zero issues at all. Most of the aperture was ok after a wire wheel. Mainly just discolouration. Around 4 areas with actual holes. This one got a little bit bigger after a wire wheel:  However most of it wasn't that bad. Scraped off the sealant in the 4 corners, and overall it could have been way way worse.  However, and there is always a "however" with these kinds of things, welding the holes up was absolute, complete and utter misery. Leaning over, back hurt, metal very thin and loved to blow holes, what a total pain. It's now done good enough for me and ground flat enough for the rubber to go back in fine, but honestly a hateful experience. Part way through sorting the 2 areas at the top:  And all done:  I also lifted back the front parts of headlining and painted rust converter on the inner edges which had some minor discolouration, but thankfully nothing more than that. Cleaned all the dirt, swarf and whatnot away and got it painted in acid etch primer:  Then I remembered I had this lying around, used this paint in the past to paint my old steering wheel. The colour was close-ish (by eye) to my old MX-5 so I had used it to paint my steering wheel. I recall it being really tough paint, and that steering wheel never chipped or anything. So I thought while it is basically hidden (apart from very thin slivers next to the rubber that were still red from before the respray), it's closer than red, so it'll do.  And it did do, almost frighteningly well actually. It's a pretty damn close match to the Toyota Ivory 😂 I added a couple of small bits of sealant over a few areas. Places that looked thin, but not actually holes. I was paranoid, and 2 layers of decent paint I thought just for my peace of mind, lets just layer these little spots with a bit of sealant.  Looks a bit ugly like that, but it'll be hidden, so I don't care. I will blade the sealant down to almost flat now it is set, so it won't interfere with the windscreen rubber. Oh yeah, the interior was absolutely covered in glass 😂 this was before I removed the screen fully:  I'd say there was 3 times as much glass by the time I was done, despite using a bed sheet to catch everything I could. It took a couple of hours with a decent hoover and by hand (the hoover was a godsend for those dusty little shards!), but I'd say 98% of the glass is now removed. The other 2% will periodically appear as and when it wants for the next few years I'm sure. Also hoovered a load out of the demist vents, but I think I will need to get into the heater exchange box at some point as some definitely made it's way all the way into there sadly. As for the screen, the Ascona screen has been acquired, and it is a laminated one. Currently at my parent's house, I'll go and grab it tomorrow evening, planning to fit Wednesday eve.  My mate at the unit has a load of experience fitting windscreens with string, so he'll be helping me to fit it. Going to buy some 3M Windscreen sealant, and just run the thinnest possible bead around the screen aperture, and also a thin bead in the glass to rubber slot all the way around the rubber seal. I noticed there was some moisture between the rubber and the frame when I removed it, so I want to prevent this occurring again. The 3M stuff is a proper windscreen sealant, not an adhesive/screen bonding product. Non-setting, and permanently flexible, which is exactly what I need for this. Hopefully all goes well, we will see! |
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1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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Yezzz
Part of things
Posts: 23
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Its never fun, but seeing that you now were able to do some rust repair, the window breaking is a bit of a blessing in disguise. Especially if you have found moisture behind the rubber.
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1981 Volvo 244 GL Turbo
1996 Mitsubishi Pajero JR ZR1
2001 Lexus IS300 Sportcross
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Its never fun, but seeing that you now were able to do some rust repair, the window breaking is a bit of a blessing in disguise. Especially if you have found moisture behind the rubber. Oh yeah, complete ballache, but long term 100% better off that this happened for sure. It needed work, and it was all hidden. Always the way, and by the time you notice it, it's really really bad in that area. |
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1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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So I picked up the windscreen from my parent's house. Wrapped it in a ton of bubble wrap and a blanket, and it literally fit on the back seat of my girlfriend's Alto by about 1cm 😂 A real tight fit! Anyway it survived the journey, so that's good at least. I got lucky this evening and as well as my mate who is pretty good with the string method, 2 other mates helped out as well. So we had someone at every section of the screen to manoeuvre it about and press where needed as the string was pulled out. I cleaned out the rubber seal first, got a few little pieces of smashed glass I missed out of it, and cleaned out a fair bit of old dry sealer, particularly from the corner sections. I thought about just using any old flexible sealant, but decided on 3M Windscreen sealant. Bit more expensive but I don't plan on doing this job twice, and it's supposed to be good stuff. Most 3M things I've had have been pretty good over the years tbh. Luckily an automotive restoration/repair place had it in stock to collect, which was ideal. Put a bead inside the rubber where the screen sits first of all, sort of trying to bead it on the front side of the seal so it will sit on the outside edge of the glass. With that done my mate filled the outer seal with the string, and I put a bead around the full windscreen aperture on the car, layering a little extra around the corners. Got the screen in with a little faff, but overall not too bad, the string method is tried and tested and it was mint to be honest.  Didn't break the screen doing it either, which was nice! Once this was done I masked the entire paint edge and with a mate using a plastic trim tool, he lifted the rubber and slid along, and I followed closely with the sealant gun. Added a layer around the entire outside edge under the rubber edge strip, and it all went in very nicely. Another mate then happened to have a diamond sort of shaped filler strip tool from his classic Mini owning days. It was a little wide for my need, so I just tapped it with a hammer to make it thinner, and it was absolutely perfect. Lubed up the channels a bit, and once I worked out how to actually use the bloody thing (thanks YouTube 😂), it got the filler strips in beautifully. A couple of small cracks in them, but none of them snapped, and all went in properly their entire length. Corner chrome pieces are all added as well.  The top filler strip I may re-visit, as it is a little too far over to the passenger side I think, but given how simple it was once we worked out how to do it properly, I can probably sort that pretty quickly. Pretty quick turnaround on this to be honest, can't complain with 5 days to recover the car, remove screen, clear out glass, source a screen, and fit it 😂 especially as I've worked 3 of those days. Once the sealer has had time to cure a bit, it doesn't set fully anyway, I'll give it a test with some water to make sure it is completely sealing, fingers crossed! |
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1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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Update: windscreen doesn't leak. Very happy that's done with! Anyway, onto something a bit more interesting. My Manifold has done well for a cobbled together Frankenstein's Monster made from pipe from 3 different cars 😂 but most of it was mild steel, and after 2 corrosion related crack repairs, it was time to change it. No point buying something fancy as it won't fit anyway without cutting in half and modifying, so I decided to give it a go myself. Now I'll note at this point, I am not a fabricator, I don't have a TIG, and until we get a decent bandsaw everything is cut with a grinder. That being said, after a bit of an ordeal I think this has come out ok. Bought a stainless flange, 2mm oversized ports, perfect to slot the pipe into to port match to the engine.  Bought various stainless bends, a pre-made 4-1 collector, stainless MIG wire, and a few other things to get it sorted.  I did some maths with the flange ports, worked out the circumference, and then worked out the circumference of the pipe I needed, so once crushed to shape it would slot inside the ports. That ended up being 41.3mm (1 5/8 inch) pipe. Started cutting the bends up to get what I needed:   This took a fair while to get perfectly to shape, and took a little beating from the inside to get them all nice and flush to the flange:  To simplify things and get the pipes all going the direction I need, I made these all 45 degrees to the flange. This also meant that it missed the heater matrix pipes, and the pipe work would all be pointing roughly down where I needed it to go. Obviously I warped the flange. I learned that even when being careful and using a heatsink, stainless loves to warp!  We did a few things to level it out, one of the most effective was 3 blow torches at the same time 😂, while it was clamped firmly down flat:  Sorted it well enough. I had a plan in mind, high rise manifold, all 4 pipes sweeping up together and down into the collector. It soon became apparent due to limited number of bends I had, and trying to keep things equal length, that this was going to be difficult.   So far so good. When it came to the 3rd and 4th bends it started looking a bit mental. I wanted to keep it equal length ish, last thing I want is for it to sound like an n/a Subaru, not ideal.  After a few head scratching moments I finally got it all routed in a way that worked. This collector is one of those slip-on collectors you use tabs and springs with, however in my infinite wisdom I thought the 42mm internal diameter of the collector slip-ons would be ok for 41.3mm OD pipe. It is not, that as it turns out is far too loose for a slip on collector. So I got a bit creative with the centre and welded it instead. Got it all welded up, and got a downpipe made up, O2 sensor bung in, and a flexi as well.  And all done:   Is it the neatest welding I've ever done? Honestly no, but it's gone pretty well and it's all working with no blows (apart from a little one from the centre or gooch of the collector if you will, I'll sort that soon). It looks a bit mental, but to be fair it doesn't sound like a Subaru so I must have done something right. Exhaust is a little louder now and the exhaust has a slightly nicer tone. Maybe it's the reduced amount of janky restrictions, or the fact the manifold is all stainless this time, not sure. Either way, pretty happy with this accomplishment! I'll get it off and polished up next weekend. |
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1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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Nath
Part of things
Memory is blank
Posts: 311 
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Oct 21, 2024 14:59:23 GMT
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bilbomk1 - I have read this from the start and has taken just over a week to achieve. That looks fantastic! The colour change (both outside & inside) compliment each other and i just love how the red POPS in your face! Gutted about the windscreen and other little niggles on the way but then it wouldn't be a project car would it?!  I'm looking at a Mk2 Escort in the same colour would be nice to get them together at a RR Meet next year if things go to plan.
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Loves anything Retro - Hates Toyotas.
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bilbomk1 - I have read this from the start and has taken just over a week to achieve. That looks fantastic! The colour change (both outside & inside) compliment each other and i just love how the red POPS in your face! Gutted about the windscreen and other little niggles on the way but then it wouldn't be a project car would it?! I'm looking at a Mk2 Escort in the same colour would be nice to get them together at a RR Meet next year if things go to plan. Haha cheers mate, long old thread now isn't it 😂 Yeah I love the colour combo. It's a little rough around the edges and there's definitely a few bits I want to get sorted soon, as well as some rust and bodywork I want to get on top of before the winter sets in properly. Yeah, had a few issues along the way, but done thousands of miles in it now, so overall it has been pretty solid! Do love a mk2 Escort, bit out of my price range these days mind 😂 You seen the raffle on Retroshite? I'm tempted to get a ticket for the beige Escort and the orange V6 Cortina haha. I try to get to Retro Rides at Goodwood every year, but we have our first baby due not too long before, so I'll see how things are getting along. Hopefully will make it though. |
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1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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Nath
Part of things
Memory is blank
Posts: 311
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bilbomk1 - I have read this from the start and has taken just over a week to achieve. That looks fantastic! The colour change (both outside & inside) compliment each other and i just love how the red POPS in your face! Gutted about the windscreen and other little niggles on the way but then it wouldn't be a project car would it?! I'm looking at a Mk2 Escort in the same colour would be nice to get them together at a RR Meet next year if things go to plan. Haha cheers mate, long old thread now isn't it Yeah I love the colour combo. It's a little rough around the edges and there's definitely a few bits I want to get sorted soon, as well as some rust and bodywork I want to get on top of before the winter sets in properly. Yeah, had a few issues along the way, but done thousands of miles in it now, so overall it has been pretty solid! Do love a mk2 Escort, bit out of my price range these days mind You seen the raffle on Retroshite? I'm tempted to get a ticket for the beige Escort and the orange V6 Cortina haha. I try to get to Retro Rides at Goodwood every year, but we have our first baby due not too long before, so I'll see how things are getting along. Hopefully will make it though. Yeah but a decent, detailed read which what i like getting my teeth into so keep it up going forwards please  . But these type of cars aren't meant to be showroom condition (imo) its called being used and treated right. And that's the main thing it looks solid and if it feels solid then you know you're doing something right. haha yeah that's the one i've got my eye on, just not sure how many tickets to buy haha i just need that MK2 in my life lol Cortina is nice also - gorgeous colour but i cant justify the 3.0L V6 for a daily  but just be a bonus having that escort as i've always wanted one and its perfect. I cant say i've ever been to a RR meet...yet just not had the right car but i need to get one ASAP and get over there now i've moved a little closer (still a 90min drive but that's nothing now). and Congratulations i know how you feel right now bud my little one is 1 now it's the best feeling ever. Just a little tip from one Dad to another - everything comes as natural (nappy changing, clothes changing etc) believe me i thought it was going to be tough but its the best thing ever having a little one!!! |
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Last Edit: Oct 22, 2024 9:05:31 GMT by Nath
Loves anything Retro - Hates Toyotas.
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Oct 22, 2024 18:32:35 GMT
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 I wont lie, I had serious doubts when you changed the colour, but that right there is the hotness. Love what you've done with the car |
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Haha cheers mate, long old thread now isn't it Yeah I love the colour combo. It's a little rough around the edges and there's definitely a few bits I want to get sorted soon, as well as some rust and bodywork I want to get on top of before the winter sets in properly. Yeah, had a few issues along the way, but done thousands of miles in it now, so overall it has been pretty solid! Do love a mk2 Escort, bit out of my price range these days mind You seen the raffle on Retroshite? I'm tempted to get a ticket for the beige Escort and the orange V6 Cortina haha. I try to get to Retro Rides at Goodwood every year, but we have our first baby due not too long before, so I'll see how things are getting along. Hopefully will make it though. Yeah but a decent, detailed read which what i like getting my teeth into so keep it up going forwards please . But these type of cars aren't meant to be showroom condition (imo) its called being used and treated right. And that's the main thing it looks solid and if it feels solid then you know you're doing something right. haha yeah that's the one i've got my eye on, just not sure how many tickets to buy haha i just need that MK2 in my life lol Cortina is nice also - gorgeous colour but i cant justify the 3.0L V6 for a daily but just be a bonus having that escort as i've always wanted one and its perfect. I cant say i've ever been to a RR meet...yet just not had the right car but i need to get one ASAP and get over there now i've moved a little closer (still a 90min drive but that's nothing now). and Congratulations i know how you feel right now bud my little one is 1 now it's the best feeling ever. Just a little tip from one Dad to another - everything comes as natural (nappy changing, clothes changing etc) believe me i thought it was going to be tough but its the best thing ever having a little one!!! Oh yeah I will continue for sure. I always did it with my MX-5s too, when people would message me asking about my DIY ITBs I just linked them to the post, saved explaining it every time 😂 Yeah it's mostly solid, just a few bits here and there that are a bit gammy really. Overall pretty solid car though now. I am tempted to grab a ticket for each on payday, free UK delivery too, so I don't need to trek to Scotland to pick it up if I won 😂 Retro Rides is honestly great. I went to Japfest quite a few times in the past back when I had the MX-5s, as well as other Japanese shows, and it was good, but there's also a lot of really bland and nasty stuff there tbh haha, I got bored of it. Retro Rides is so wild in variety of cars, as well as modifications, it's always cool seeing the mad stuff people build. Haha cheers, I'm sure it will all fall into place, but right now I've not got a clue how to do any of it 😂 I wont lie, I had serious doubts when you changed the colour, but that right there is the hotness. Love what you've done with the car Cheers mate, appreciate it. I'll admit it probably isn't a colour to everyone's tastes, but I've always loved the cream and red colour scheme on so many different cars, I just had to do it. Looks great in that photo, I really should give it a proper wash, it's filthy at the minute 😂 |
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1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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I'm looking at a Mk2 Escort in the same colour would be nice to get them together at a RR Meet next year if things go to plan.
. But these type of cars aren't meant to be showroom condition (imo) its called being used and treated right. And that's the main thing it looks solid and if it feels solid then you know you're doing something right. 
but just be a bonus having that escort as i've always wanted one and its perfect. 