Complete Car Building Guide
Master the ultimate challenge: building the Corris Rivett from rust to 99hp winter warrior. Complete engine, transmission, and suspension assembly.
AdvancedMechanicalTime IntensiveLast updated: 2025-12-30
25-50k+ mk
Total Cost
20-40 hrs
Build Time
99 hp
Final Power
Intermediate
Skill Level
Corris Rivett - Complete Build Process
Overview
The ultimate step-by-step guide to building the Corris Rivett from a rusty shell to a 99hp winter warrior. Master engine rebuilding, transmission repair, suspension setup, and more.
Required Skills
- Basic mechanical knowledge - Engine components, fasteners
- Patience - Things will go wrong
- Problem solving - When parts don't fit
- Budget management - Costs spiral easily
- Winter resilience - Working in cold conditions
You'll Learn
- Engine rebuilding
- Transmission repair
- Suspension geometry
- Electrical systems
- Bodywork basics
- Painting techniques
Budget Breakdown
vehicle Purchase
Project car quality varies
15,000 mk - 25,000 mk
engine Transmission
Block, head, gearbox
3,000 mk - 8,000 mk
suspension Brakes
Springs, shocks, discs
2,000 mk - 4,000 mk
electrical Interior
Harness, seats, dashboard
1,500 mk - 3,000 mk
body Paint
Panels, rust repair
2,000 mk - 5,000 mk
tools
If you don't have them
500 mk - 1,500 mk
labor
Complex work at Fleetari
2,000 mk - 5,000 mk
total
Complete build
26,000 mk - 51,500 mk
Build Phases
Day 1-2Critical
Pre-Build Planning
Phase 1
Tasks:
- Secure Futufon job for income
- Save 30,000+ mk minimum budget
- Find garage space to work
- Purchase classifieds magazine
- Inspect potential project cars
- Complete vehicle purchase
💡 Tips:
- • Budget reality check: This project costs 25-50k+ mk
- • Don't rush - take time to find the right car
- • Get a vehicle with minimal rust
⚠️ Warnings:
- • This is an expensive project - secure income first
- • Avoid cars with frame rust - it's a killer
Week 1-2Critical
Engine Rebuild
Phase 2
Tasks:
- Drain all fluids (oil, coolant, fuel)
- Remove accessories (alternator, water pump, starter)
- Remove intake/exhaust manifolds
- Remove valve cover and cylinder head
- Remove timing components (belt, pulleys, tensioner)
- Remove oil pan and extract pistons/rods
- Remove crankshaft for inspection
- Clean and inspect block for cracks
- Measure crankshaft journals and cylinder bores
- Install crankshaft with main bearings
- Install pistons and connecting rods
- Rebuild cylinder head (valves, guides, springs)
- Install timing belt system (CRITICAL - check alignment)
- Install cylinder head with new gasket
- Install all accessories and manifolds
💡 Tips:
- • This is an INTERFERENCE ENGINE - timing belt alignment is critical
- • Use NEW belt, tensioner, and idlers
- • Double-check all timing marks before starting engine
⚠️ Warnings:
- • Timing belt failure destroys valves and pistons
- • Never reuse a head gasket
- • Over-tightening damages water pump bearings
3
Week 2-3
Transmission & Clutch
Phase 3
Tasks:
- Remove transmission from engine
- Disassemble gearbox for inspection
- Check synchros and bearings for wear
- Measure clearances and replace worn parts
- Reassemble transmission with new seals
- Replace clutch disc (wears out)
- Inspect flywheel for cracks or scoring
- Install pressure plate and clutch disc
- Bleed hydraulic clutch system
- Install transmission back to engine
- Install driveshaft (11-12mm bolts to differential)
- Check rear differential and axle
💡 Tips:
- • 5-speed overdrive better for highway, 4-speed better for snow
- • Clutch disc must face correct direction
- • Torque pressure plate bolts evenly
⚠️ Warnings:
- • Don't drive with bad brakes
- • Test thoroughly before driving
Week 3-4Critical
Suspension & Brakes
Phase 4
Tasks:
- Remove front wheels and support vehicle safely
- Disconnect sway bar link ends
- Remove MacPherson struts (top and bottom bolts)
- Compress springs and replace struts/mounts
- Install new springs in struts
- Install front suspension components
- Support rear axle with bottle jack
- Remove rear springs and 4-link arms
- Inspect bushings for wear
- Install new rear suspension components
- Remove front calipers and brake pads
- Inspect rotors for thickness and runout
- Install new brake pads
- Bleed brake system with new fluid
- Check rear drum brakes and adjust
💡 Tips:
- • Get wheel alignment after suspension work
- • Use quality brake pads
- • Check tire pressure after installation
⚠️ Warnings:
- • Never drive with bad brakes
- • Support vehicle with jack stands
5
Week 4-5
Electrical & Fuel System
Phase 5
Tasks:
- Install wiring harness
- Connect ignition system (distributor, coil, plugs)
- Test and charge battery (12.6V minimum)
- Check all ground connections
- Install and test alternator
- Adjust alternator belt tension
- Connect lighting system (headlights, taillights)
- Install mechanical fuel pump
- Connect fuel lines (check for cracks)
- Install and tune carburetor
- Set air-fuel ratio for winter (13.5-14.0 AFR)
- Test fuel pressure (3-5 PSI)
- Install dashboard components
- Connect wipers, heater, radio
💡 Tips:
- • Clean, tight ground connections are critical
- • Winter needs richer fuel mixture
- • Block heater makes starting easier
⚠️ Warnings:
- • Check battery voltage before starting
- • Fuel leaks are dangerous - test thoroughly
6
Week 5-6
Interior & Exterior
Phase 6
Tasks:
- Install front bucket seats
- Install rear bench seat
- Install instrument cluster
- Connect all dashboard switches
- Install or repair door mechanisms
- Check hood alignment and hinges
- Repair any body rust or dents
- Prime and paint body panels
- Install exterior trim and moldings
- Lubricate all moving parts
- Final interior cleanup
💡 Tips:
- • Take photos during disassembly for reassembly
- • Quality paint job adds significant value
- • Lubrication prevents squeaks and binding
⚠️ Warnings:
- • Wear proper safety gear when painting
- • Check all safety systems before driving
Week 6-8Critical
Testing & Break-In
Phase 7
Tasks:
- Check all fluid levels (oil, coolant, brake)
- Prime oil system with starter
- Verify timing marks one final time
- Pressurize fuel system and check for leaks
- Ensure battery is fully charged
- Initial start-up (don't touch throttle)
- Listen for unusual noises
- Check for fluid leaks
- Gradually increase RPM to 2000
- Break-in driving (first 500 km)
- Vary RPM, avoid wide open throttle
- Check oil level frequently
- Monitor engine temperature
- Change oil after 500 km
- Torque check all bolts
- Fine-tune valve lash
- Adjust idle speed and timing
- Final alignment check
💡 Tips:
- • If you hear valve contact - IMMEDIATELY SHUT OFF
- • Gentle driving for first 500 km is critical
- • Document any issues during break-in
⚠️ Warnings:
- • Timing errors cause catastrophic damage
- • Never skip the break-in period
- • Test brakes thoroughly before highway speeds
Troubleshooting Guide
Engine Won't Start
No spark
- •Check battery voltage
- •Test ignition coil
- •Check distributor points/electronic ignition
- •Test spark plugs
No fuel
- •Check fuel pump operation
- •Pressurize carburetor
- •Check fuel filter
- •Check tank for fuel
Timing off
- •Check timing marks alignment
- •Verify belt installation
- •Check crank keyway
- •Verify cam lobe position
Rough Idle Causes
- •Vacuum leak (intake manifold)
- •Ignition timing off
- •Carburetor needs adjustment
- •Faulty spark plug(s)
- •Low compression
Overheating Causes
- •Low coolant level
- •Bad thermostat
- •Faulty water pump
- •Blocked radiator
- •Air in cooling system
Maintenance Schedule
First Week & Month
First Week
- Daily: Check oil level
- Daily: Check coolant level
- After 100 km: Torque check bolts
- After 500 km: Oil change
First Month
- Oil change (500 km)
- Coolant check
- Brake fluid check
- Belt tension check
- Tire pressure check
Ongoing Maintenance
First 3 Months
- Transmission fluid change
- Brake inspection
- Suspension inspection
- Alignment check
- Complete tune-up
Ongoing
- Oil change every 5,000 km
- Coolant change every 2 years
- Timing belt every 60,000 km
- Brake fluid every 2 years
- Transmission service every 30,000 km
Critical Warnings
- ⚠The 2.0L OHC is an interference engine. If the timing belt breaks, pistons smash valves, destroying the head. Always replace the timing belt first on any used engine!
- ⚠A complete Corris Rivett restoration costs 25,000-50,000+ mk. This is not a cheap project. Secure stable income (Futufon job) before starting.
Pro Tips
- ✓Use quality parts - cheap parts fail
- ✓Document everything - take photos, notes
- ✓Take your time - rushing leads to mistakes
- ✓Get help when needed - Fleetari, forums, guides