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Sept 23, 2022 19:23:41 GMT
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Good progress, that chassis section that's already been repaired is a common area to rot on Mk1s.
In the inner wing is a drain hole at the back, that drains water into this area but as it is triple skinned and there's no way for the water to fully drain out then it rots from the inside out.
When you see it blowing out the metal then it's bad. My Cavalier suffered here and there was a fair bit of work to rectify it properly which included the engine and box coming out and the engine bed being dropped down. Once repaired i drilled holes inside and every so often i now inject wax in there.
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1980 Vauxhall Cavalier MK1
1970 Mobyleete 40T custom
1978 Mobylette 50V
1965 Moulton Standard
1979 Raleigh Grifter custom
1980 Raleigh Grifter
1982 Raleigh Grifter BMX custom
1982 Raleigh Bomber
1987 Strida
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Sept 23, 2022 19:29:51 GMT
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Great work so far. Seized brake calipers are always fun to work with, don't blame you using bigg red. For reference, I believe BMW E21 had the same calipers... Now *that* is useful to know. At least based on the photos in listings they definitely do look the same, and quite a few of the usual suspects do actually list them as in stock, unlike when searching for the Cavalier. They're still £100 plus change each (plus VAT and delivery) though so I reckon refurb probably still makes decent sense. Personally I'd trust one of these calipers that's been overhauled by a reputable workshop to the one brand that Autodoc have listed that I've never heard of and has probably been sitting on a shelf for goodness knows how long. Plus if they then send me the wrong part I'm then stuck with it because their returns process is such an utter pain. Even when they have flat out sent the wrong part. There's far too much throwing away of things in the world these days too, so doing a little to reduce that just feels like a sensible thing to do. |
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Current fleet: 73 AC Model-70. 75 Rover 3500. 84 Trabant 601S. 85 Sinclair C5. 06 Peugeot Partner 1.6HDi.
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sleag40
Part of things
I've no longer space for any more!
Posts: 880 
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Sept 23, 2022 20:14:26 GMT
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Definitely a good call using Bigg Red - these are the same type of calipers as yours once given their treatment.  Still going strong six years later on my Cav.  |
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1994 Volkswagen Polo G40
1992 Volkswagen Polo G40
1988 Vauxhall Cavalier GLi
1977 Vauxhall Cavalier GL
1973 Renault 15TS
1967 Lambretta SX200
1966 Lambretta TV200
1964 Lambretta LI150
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Sept 24, 2022 21:50:26 GMT
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This afternoon I played chicken with the weather. This was rapidly bearing down on my position.  Mission was simple: Get the offside brake caliper off the Cavalier so I could get the pair sent off to be rebuilt. In a rare show of organisation, I actually made a point of getting everything I expected to need out in advance and putting it where I could get to it, rather than the usual 15 trips back and forward to the garage.  Five minutes later, first contact with the enemy.  I was briefly sidetracked by a sinister looking bit of peeling seam sealer on the inner wheel arch, but thankfully I seem to have caught it in time.  Really isn't hard to see why these cars have a reputation for rusting. Thanks to the wonders of power tools, less than ten minutes after picking tools up I had the caliper off, wheel back on and the jack back in the boot. The little bag the jack and wheel brace live in are even colour coded to the car, how considerate of Vauxhall...  Yes I know they're just all that colour, but it amused me. This is where we took a moment of "one step forward, two steps sideways."  These two calipers are not the same.  The one on the offside is made by Girling.  Whereas the nearside one is an ATE.  Not really surprising that the car has had one changed, but it's rather annoying as it means I don't have a matched pair to send off for rebuild. I'm also rather alarmed that the pads in each side are a totally different brand with a significant difference in the amount of wear on them...so it seems that whoever changed the nearside caliper didn't bother swapping the offside pads when it went on... additionally the lower caliper to hub bolt was missing it's washer...You remember me saying I was going to test the rear brakes before pulling things apart? Nope...on the strength of this, they're definitely getting properly inspected beforehand now. Don't suppose anyone has an old nearside Girling caliper floating around do they? Did spot something I'd previously missed that was a quick fix (well, it still needs a little attention but is a lot better). Spot the difference.   The valance had been shoved upwards on the offside. It still needs a little finessing and whatever did the damage has broken off one of the tabs where it attaches to the lower part of the wing, but it's a lot better.  So a little stuck while I decide what to do about the brakes. If I can't track down either another ATE or Girling caliper I will probably just end up buying a new pair, as don't want to hold this up too long. |
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Current fleet: 73 AC Model-70. 75 Rover 3500. 84 Trabant 601S. 85 Sinclair C5. 06 Peugeot Partner 1.6HDi.
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Sept 27, 2022 8:35:05 GMT
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Great to see another mk1 being given some love on here! Mine has proven to be a fair bit more rusty than yours seems to be, which is unsurprising I guess as it's been sat since 1997 haha.
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1980 Vauxhall Cavalier - MX-5 VVT engine/box conversion, GSXR ITBs
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Sept 28, 2022 17:09:36 GMT
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I have few calipers of these Ascona B's but I'm from the Netherlands so shipping is not cheap.
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Sept 29, 2022 20:26:12 GMT
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I have few calipers of these Ascona B's but I'm from the Netherlands so shipping is not cheap. To be honest, last time I've had a few things shipped to/from the EU I've not found it to be too painful. Aside from the time that someone put the NEW value on the customs declaration for an ancient bit of computer equipment rather than what it had been sold for anyway...That stung! As it stands I'm a bit stuck - I currently have two mismatched calipers, so can't just send them off for refurb. I'm not 100% on the compatibility of the BMW E21 calipers as while they LOOK identical as far as I can tell, the part numbers do differ. I'm not sure if that's something daft like the pipe union being metric on one and imperial on another (which is trivial - there's a 3" or so hard line between the caliper and the flexible line - I just put the relevant fitting on the end of that!)...But without an actual proper diagram or absolute confirmation from someone who's done it I'm not about to drop probably the best part of £300 on a pair of calipers which MIGHT fit. If you've got a spare caliper you'd be willing to part with which would give me a matched pair I could pack off to be rebuilt I'd definitely be interested. |
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Current fleet: 73 AC Model-70. 75 Rover 3500. 84 Trabant 601S. 85 Sinclair C5. 06 Peugeot Partner 1.6HDi.
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Ill take some pictures later today of the calipers.
*Edit* my dad scrapt them..
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Last Edit: Oct 2, 2022 13:03:26 GMT by jelmerv8
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Currently away from home in the US, so will have nothing to report car wise for a bit. Though assuming the part numbers are correct I *should* have a factory rebuilt ATE brake caliper for the Cavalier on the way. So when I'm back I should be able to get the ball rolling there.
If it looks like the caliper was rebuilt back in the 90s as I'm kind of expecting, they'll both be sent off to Bigg Red to be given a good once over. Which I'm kind of inclined to do anyway in the interests of long term reliability.
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Current fleet: 73 AC Model-70. 75 Rover 3500. 84 Trabant 601S. 85 Sinclair C5. 06 Peugeot Partner 1.6HDi.
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Apparently the new caliper has now arrived back home. Sadly I'm currently 3,500 miles away from the car so it'll need to wait for attention!
Whether that caliper gets sent off along with the original one for inspection and any necessary rebuild work will depend on what it looks like. I may well send them both away anyway for the sake of long term reliability anyway. It's not as though I can start putting stuff back together properly until they're both present anyway. It *looks* good in the photos on the eBay listing, but we all know how much that means.
Also on the subject of brakes, discs. Am I correct in thinking that the wheel bearing races are pressed into the discs on these? I've got a new pair of discs in the boot waiting to go on, but will get a bearing set ordered too if that's the case. If I need to take everything apart anyway I'm inclined to just change the consumables involved to save me time and head off future failures before they have a chance to pop up.
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Current fleet: 73 AC Model-70. 75 Rover 3500. 84 Trabant 601S. 85 Sinclair C5. 06 Peugeot Partner 1.6HDi.
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It's been a long time since I looked at one of these but I'm pretty sure they are like cortinas and mk2 escorts, you take the hub and disc off as an assembly by undoing the centre nut then there 4 bolts which hold the disc to the back of the hub, you could change the bearings while you are there but there's no need to just cover them to keep any dirt and rust out when you remove the disc.
The outer bearing will fall out so be carefull to catch it, the inner should be retained by the oil seal.
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It's been a long time since I looked at one of these but I'm pretty sure they are like cortinas and mk2 escorts, you take the hub and disc off as an assembly by undoing the centre nut then there 4 bolts which hold the disc to the back of the hub, you could change the bearings while you are there but there's no need to just cover them to keep any dirt and rust out when you remove the disc. The outer bearing will fall out so be carefull to catch it, the inner should be retained by the oil seal. Thanks. Been a while since I've changed a bearing that isn't pressed into the disc. Sounds like that should be pleasantly simple in comparison then. If we don't need to faff about with presses and the like I'll just inspect the bearings while I'm in there then. |
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Current fleet: 73 AC Model-70. 75 Rover 3500. 84 Trabant 601S. 85 Sinclair C5. 06 Peugeot Partner 1.6HDi.
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Oct 17, 2022 14:51:01 GMT
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Back home and trying to get caught up with things. While jetlagged to hell and back (yesterday was effectively a 32 hour day - got absolutely zero sleep on the flight - by the time I eventually fell into bed). Oh, and we had contractors arrive at 0830 this morning to start replacing our roof. Yeah, genius bit of programming on my part there. Though in fairness it's the date I was given and with the trouble we've had getting folks in I just took it. Firstly I've confirmed that the new caliper for the Cavalier will be going off to be inspected and rebuilt as necessary with the one that came off the car. Yes it's a factory remanufactured part - but as I kind of expected, that looks to have happened somewhere probably in the 1990s and it's sat somewhere less than entirely dry since.  Would probably be fine, but I figure if I'm getting one sorted I may as well just get the pair seen to. Less likely to come back to bite me then. The other car related item was a sample replacement wheel stud for the Invacar which is detailed over on the respective thread. |
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Current fleet: 73 AC Model-70. 75 Rover 3500. 84 Trabant 601S. 85 Sinclair C5. 06 Peugeot Partner 1.6HDi.
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great stuff, big fan of these old cavs, my dad had a few of them and my aunt had an ascona id love to get hold of one now! jumping back a bit, when the gearbox was changed was the engine also swapped? yes it makes sense that the interior bits are manta but the box and engine could have come from a carlton, they came with 2.0 and 2.2 cih lumps, could be worth decoding engine numbers? or the original carb could have been put on a manta engine, and tweaked just a thought! could expain the diz being different, also a possibility for the odd brakes could be someone swapped a full strut over, to get it back on the road quick! manta brakes should still be fairly easy to get here too!
mechless stereo is the way id go, probably try make the console fit in better. the 4 speed cavs gearstick came out further forward, but yours originally being auto I'm not sure where the cable would have passed thru but I'm sure you shouldnt have a hole in the carpet under the console worth thinking about if you want to remove it!
cant remember last time i saw one that wasnt red or blue! used to be a proper 70s orange one local many years ago.
clutches i imagine should be the same as all cih mantas and carltons, possibly some cih engined frontera's (assuming gearbox input shaft splines are the same!) but obviously not the 1256 cav or the 1800 ohc manta. no idea about the 6 cyl cih clutches either! theoretically should be similar but gearbox splines possibly different.
another edit lol plug leads look like there specced for the ohc engine with the heat shields as the plugs are on the exhaust side but on the cih the exhaust is on the opposite side, no real difference but remember the ohc ones with the heat shields used to cost more than the standard leads!
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 2006 Audi A3 2003 Fusion 2 looking for a project.... |
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