1977 Vauxhall Cavalier 1600 GL

The first major thing we had to iron out was to why the Hazard Lights wouldn’t flash and the Main Beam being defunct. The Quartz Clock and Interior Light where shot. The Mixture was to Rich and the Tappets needed sorting.

The lights and clock issue was easily rectified by replacing all the fuse banks with a set of 50 fuses off of Ebay for a decent price of £4.

Pretty much soon after we whipped the Rocker Cover off to sort the tappets out and replace the weeping Rocker Cover Gasket, following the Rule of 9 with my dad was an entirely new concept to me. Tappets sorted and the Cork Gasket on we noted that the Rocker Cover had warped over time around the bolt holes so we simply straightened it out and it’s dry as a bone!

We also painted the Cover Black as it was originally quite dirty and cruddy. A set of new HT Leads and a RamAir Air Filter was in store as the original was heavily Spoiled. We also redirected the Oil Feed to down the side of the engine and blanked it off the Carburettor end. Thankfully it came equipped with a 32/36 DGV as that was going to be a must have if it didn’t.

It comes fitted with Spax Shocks and Lowering Springs, i’m unsure whether they are adjustable as the ride is very very firm.

Another R Reg! Amazing! Much better nick than mine. Isn’t that Sky Blue?

It looks brilliant! I’ll definitely keep tabs as i’d like mine to be all done up soon.

Perfect! It’s always interesting to know more about this car as each day comes! I look forward to meeting Cav owners in person!

The plan really is to bring it back to show standard but use it how it should be, the plan in the future is to transplant the 2 Litre CIH or at a push the 2.3 Slant 4 just for the power. Mainly keep it in tone to almost original. I just want myself and others to enjoy it!

In January and February nothing more was really undertaken other than the Goodmans Cassette Deck failed and was replaced by a Kenwood KRC 658 R, we got the front speaker finally wired back up as the Goodmans was only a 2 Channel and not a 4 like the Kenwood.

A few pictures were taken in the meantime as i trialled new things including running the car with no front bumper as i sorted the sag on one side.










We also removed the restricted and poorly fitted muffler for a Cherry Bomb that was given for free from a friend, loud but appropriate and gives a nice rasp as well as it having a Chrome Rolled Tip! Something i was going to have fitted later down the line!

Well, It has been a while since I last updated this Thread, we are in July now and much has changed on TVG since March. Apologies if I miss out on some key details, I will try and fill in where best!

Let's Re-Cap!

Well some of you keen readers might have picked up on me wanting to mess around with some different wheels if I could get my hands on a set. After a chat with my Father who had a 1976 Vauxhall Cavalier who gave it the typical 80's Boy Racer feel; Straight Pipe, Spotlights, Wheels, Carb Conversion.... We came to conclusion a good set of 4x100 Weller Steel Wheels, Now god was this a mission by itself as it seems Weller's on the Used Market are keen with the PCD of Ford's and Commonly found to be mated to some Escort Mk1/2 Rally Car.

To mine and my Dad's surprise I found a 'Battered' Set in Gloucester (A whole 110-130 Mile so Journey for me) which for the grand sum of £150 for 7 Wheels was a no brainer, Bonus they Came with Yoko Rally Tyres but I just wanted the wheels. 4 in 4x100 (Perfect) and 3 in Ford PCD (Typical). At the same time I ferried these wheels back to my house I decided the No Bumper / Blue Splitter look was utterly dreadful so the bumper was re-fitted (Straight this time) and Re-Painted the Splitter in a more sportier Satin Black....Wow, what a difference that made.

On went the Wellers and this is where things went wrong (lol), the radius was bang on 13 inch which was what I was looking for, 8 Inch wide so they filled the Arches perfectly....Nothings smooth sailing as we all know....All 4 Yoko's were 175/55 and paired with an already slammed 70's Classic meant I couldn't get off the drive whatsoever, great, but not to mention the Near-Side Rear Yoko was heavily leaking air.

Off to the Tyre Bay to be removed an the N/S Rear Tyre had been completely chewed up on the inside, and to add salt in the wounds all 4 Wheels were far from straight on a Balancing Machine (Luckily they are Steel so can easily be manipulated).

Pictures to follow including the Cavaliers first Car Meet since I re-painted and re-fitted everything. Thankfully you are all caught up with March.

Now onto June......Ohhhhhh Boy have I been excited to tell you lot!

Now before I continue I could potentially loose the interest (If haven't already) of Die-Hard Vauxhall Purists.....

in Early May Myself and my Dad toyed with the idea of more power (something the Cavalier looked like it had.....but didn't) and a few Intriguing ideas came to the board; 2.3 Slant 4, 2.4 CIH, 2.2 CIH, 2.0E CIH, 2.0S CIH..

I took the plunge in Mid-May to Purchase a 2 Litre Cam-In-Head E from the Opel Manta GT/E Including all Running Gear (Dashboard, Leccy Ignition, Gearbox, Prop Shaft, Rear Axle, Engine...But with a twist! I which some might find strange opted for the Fuel Injection System to be completely removed as I'm sticking with the trust Carb route.

Disclaimer... There's method behind my madness...

the Engine I have purchased came out of a 1987 Exclusive Manta which was spec'd with the super rare Opel Tuning Package (Cam, Skimmed Head) to make standard guise of 110 hp bump to 123 hp (Correct figure if I remember correctly). The main ambition for me running carbs was to eventually run twin 45 DCOE's but a few opinions were noted on the OMOC Forum for a 38 DGAS Carb with Syncro Throttle Linkage.

I wanted what from an untrained eye looked like a 1600 Engine until you dug deeper and discovered a de-evolution 2 Litre E engine, the 2 Litre S is viable from the B1 Manta / Ascona / Cavalier but I like the sound of what the GT/E Engine had to offer in factory guise.


Next Post.......The Strip-Down!!

I tried to post in Picture Order but RR's Picture Uploader had other ideas haha.

Gone with the important stuff other than the remainder of the Engine and the Axle, we move into the Interior.

A-bit of a grey area in all honesty, I was supplied with the respective Instrument Panel from the Exclusive Inc. the Centre Console so was soon eager to get all the wiring set in stone to make life easier down the line. As mentioned sometime in Feb / March I'd trailed a 6 Clock Dash in my 1600 but due to a bad earth and a dodgy repair done in the past I blew the circuit board (Lesson Learned).....

Out came the old 3 Clock Dash and with it I severed the original 11 Pin Dash Connector to make way for another which was wired for a 6 Clock (Easier than re-sorting pins or chopping and changing)...Pictures Supplied of that! This was a grey area for me so I really hope this benefits someone. One thing which is different is the addition of a Tachometer and the Main Beam being re-routed from the 11 Pin to the Half Moon Pin with the Tacho (This is because there is a 2nd Oil Pressure wire on the 11 Pin for the 6 Clock).

Along the way of re-wiring and making a bundle of new wires myself I began to 'wrap' my Exposed Red Wires in tape to disguise it as an OE Look, more for shows as it was something similar to a 'Turn Off' to keen eyed car enthusiasts, I guess also a good excuse for 'Wire Management'.

I Managed to source 2 Black Dashboard Covers as my original Beige one has been heavily sun-bleached and cracked as a result, I think it suits but I am keen for other opinions of course.

My next topic is the Conversion from 4Spd to 5Spd, it's another grey area on forums as most don't simply do it or there's no need as GT/E's come factory with a 5Spd. The Getrag 5 is smaller than the 4 but the linkage sits closer to the driver and as a result a different centre console is required + the Manta got a Tape Tray which is super cool. When removing the Centre Console there is an elongated section of Tunnel which is left un-carpeted as though it was designed to fit a 5Spd later on down the line, all that is needed is to cut/elongate the original hole and weld a plate where the original sits to eliminate wind noise. Pictured Below.

Oh and of course it was standard procedure that I filled the Tape Tray haha.


Well guys and girls, you are all caught up for now....sorry!! but my plans follow so please stay involved, I look forward to hearing Opinions!;

Sunday (where fit) - Clean/Degrease Gearbox and Prop ready for some Paint! I aim for a Sliver Box with Getrag Painted Black (a Subtle Touch)
Monday - Remove Rear Axle / Potentially Re-Fit 20E Axle but not without a lick of Paint!
Mid-Week - Look to source a viable Engine Crane
Weekend - If a Crane is Sourced, Remove 1600 Engine, Clean 20E on the Crane and Potentially Re-Fit


The most hardest part to come is the gearbox, it should be relatively easy but includes a lot of fettling.

I'm so excited and counting down the days to finally turn that key and hit the road!!