13 replies to this topic

[Kevin Abbott]

As I can't find ( after plenty of searching ) my project thread and with the old one being all messed up due to it being an old thread I will start again
I bought the car 12 years ago and set about the task of buying and fitting a cosworth engine and box


Opel Manta coupe,  the best shell I have had in 20 years and owned by a lady and the car had only 40 thousand miles on the clock
Back in the day digital cameras didn't exist so I have no pics of it as it was :'(


Hey ho.....   cosworth engine added and t5 box






manta i240 bodykit from the best in the country( rallytech)


T5 box a bit long for the manta so I sierra tunnel added although I now may go back to a getrag 265 and manta tunnel :'(



Manta pcd is 4x100 and I wanted 5 x120 so hubs changed to monza with manta bearings custom made at a cost of 200 quid so I could pick and choose bmw rims
These are harge split rims



Other rims to consider are these which seem to fill the arch better




The roof on a manta is rubbish so I cut it off and added a non sunroof one





And lead fill





Manta brakes, deathwish so m3 discs and integralle calipers







RS500 intercooler tucked into nose




cage added






manta steering is always really heavy( honestly it can be a 2 hand job just to turn and that leaves no hands for stirring the box :-X)  on a lowered car so I added corsa b column power steering


Then I added EPS



Corsa b column



Remove the outer collapsable top part of the corsa bit



You are left with




Don't hit the end of the spline as I did or the spline end will come off



I will be putting a blob of weld on mine to hold the 2 parts together as the top part with the manta bit added will not collapse now anyway, the reference for the amount to stick out is 85mm for the top part




Take your manta column and remove the inside part




What I was trying to do was keep the columns the same length so the inner part was my reference point




Take the outside of the manta column and chop it into 3 pieces

Edited by Kevin Abbott, 22 January 2012 - 12:46 AM.

[Kevin Abbott]

Giving away my mancona and seeing Johns project gave me a kick up the arse.
So.
Iv'e never liked the T5 and sierra tunnel... Yuk


After a little googling I found out the RS500 Touring cars used a Getrag box, the 265
I have a couple lying around so what the hell.

265 monza box, yea
Need to join the two

Ali adaptor ( cheers Cliff )

Cut big hole in T5 bellhousing

10 hours of measuring and measuring and measuring and swarf everywhere

That's just together, not bolted up yet, spigot not done
Spigot was a PITA, tried getting it out of the cossie ... Arrrrrghhhhhh, ended up welding a nut to the race and drifted it out

New oilite bearing fitted ( thank's Rutts ) after boiling it in oil


It went a different colour

Info, Sierra cosworth spigot bearing outer is 21mm, inner 14mm
Manta outer 21mm, inner 15mm
I needed a 21OD, 12ID

Lots of angle measurements later as I had built a stand for the YB to sit the engine at 4 degree to Exhaust and the box had to be level


Bolted up

Edited by Kevin Abbott, 15 February 2012 - 07:10 PM.

[johno]

VERY NICE PROJECT!!

[robah]

So this is the car Danny mentioned at the chrimbo function . Nice to see someone taking as long as I am to get there ar5e in gear.

[danko_f4]

very nice car

What is the rear diferencial

[opelmantagsi]

great effort so far, looks awesome. whats the plan with the engine mounts?

[peter evans]

hi kev its peter i bought the roof skin from you do you have a lsd for sale?
thanks peter

[Kevin Abbott]

Post is a bit topsy turvy due to me not being able to add more pictures to the first bit

I now have a ' Martin' 400 kit for it and hope to bring the car home next week.
Loads of new stuff bought for it
Thank's to Rutts I have an original tunnel to go back into it too

You want the top outer part to be 180mm




That part slips over the inner of the corsa bit



These two parts will be welded together



Make room to get at the bolts



This will now take the manta multi switchgear and wheel in the same place as a standard car



Bottom part of the column

Take the inner shaft from the manta and split it then cut the bottom part down to 315mm









Take the bottom part of the outer of the manta column and bolt it to the floor, mine hasn't got a bearing in as it will be blasted and a new one fitted

Column will now bolt into place as the original








It fits in the bay as the standard one does


I got the column myself so removed lots of wiring and got the fuseholer that was standard in the car











I settled on the 4ha mega axle as used by scimitar, jaguar and aston martin as it is unbreakable
Pic is a 4ha compared to a 400 type axle


I removed the axle from a scimitar gte and it was a 4 hour fight, at the end of it the bloke who owned the yard felt sorry for me and carried it to my volvo


PCD on the hub is 4x108 and I need 5x 120 so I went out and got a set of geometry school stuff, plotted the center of the scimitar and the bmw and transfered it onto graph paper


So after a plug on one hole

And a weld then grind flat

The 5x120 can be drilled

I had to add a milled surface for the back of the stud parallel to the hub so I got a counter bore drill



It did this

Studs in and ready for the wheels


I am removing the links from the 4ha and replacing them with 400 type ones


This is the xjs axle that is hiding the 4ha LSD. The only axle I have ever had to take apart with a sledgehammer



Sorry Peter, i sold the rebuilt ZF I had on it.
Engine mounts are done,
http://img.photobuck...er/85c7b08c.jpg
Other side harder to see as I had to use a cosworth 4x4 oil filter extension
http://img.photobuck...er/9fc4de09.jpg

[opelmantagsi]

cool, so what is the plan for between the mount on the block and the fixing point on the sub frame? rubber bobbins or solid mounts?

[Danny D114BCW]

Sorry to crash this thread for a second but Peter, Gripper do a good slippy diff thats based on the ZF type. Kev car looks great and its been a great shelf for nearly 10years i have known ya haha but no it does look good.

[Ivan1969]

super

[garymanc]

peter evans, on 15 February 2012 - 07:27 AM, said:

hi kev its peter i bought the roof skin from you do you have a lsd for sale?
thanks peter

http://totalopel.com...ead.php?t=17620 in ireland
car is looking good kev,when will it be finished

[Kevin Abbott]

garymanc, on 17 February 2012 - 01:00 AM, said:

http://totalopel.com...ead.php?t=17620 in ireland
car is looking good kev,when will it be finished

For Billing

[mickappy]

which year kev;-).