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01656 818804
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Sat 9.00am-12.00 Midday

TJ Motorsport
45 Allt Dderw
S Wales
CF31 5BZ

Visits are by appointment only



Historic Chevette Rallycar Build

Historic Specification Category 3 Vauxhall Chevette HS2300 Build

(Homologation Paper No 649):

Below will be the complete documented build of TJ Motorsport's latest historic specification Vauxhall Chevette. Where do we start - with a 51000 mile 1979 Vauxhall Chevette GL 1256cc in very good condition.

The Stripdown:

All major components have been removed to include engine, gearbox, propshaft and rear axle along with all ancilliaries.

Group 4 Bodykit Test Fit

Before removing any bodywork it was time to test fit the Group 4 Fibreglass Bodykit. This bodykit was manufactured using the original DTV moulds that have been painstakingly refurbished ensuring with minor trimming an excellent fit with little to no orangepeel in the final gel coat. This bodykit is now available to order from TJ Motorsport taking approximately 3 weeks to get made.


Bodywork Fabrication and Preparation:

Starting at the front end of the car it was time to assess what panels required rust removal and repair. The usual suspects soom came to light, wing mounting rail, splash panel, inner wing reinforcement and windscreen scuttle ends.



As it is very difficult to source replacement panels for some of this damage then the only answer is to manufacture. Starting with mild steel sheet metal, folding, flanging and butt welding to end up with the following results. The inner wing repair panel is manufactured from scratch, however the rear inner wing reinforcement is available to purchase HERE, direct from TJ Motorsport.


Now moving onto the wing mounting rail, cut and folded some 16swg mild steel, trimmed inner wing to ensure tight fit for butt welding, allowing us to then sand the welds to make invisible.


To finish off the top of the inner wing a major repair was needed to the front section which always rust. A lot more panel beating and shaping was required to create this panel.



As this car will be used for motorsport we decided to uprate the front suspension turrets. These items are made thicker and normally used for converting the shell to long wheel base as per the motorsport HSR. Firstly a jig was manufactured to ensure the turrets were placed back in exactly the same position.



Just started making more room for a decent alloy radiator and oil cooler. A large amount og the inner front panel has been removed to accomodate these upgrades.


What I need now is a way to turn the whole car over. So lets build a car rotisserie, this is what I came up with.