taylorblue5 Posted October 2, 2012 Author Share Posted October 2, 2012 Funny really, masked up the car n started spraying the realised the skirts were still inside lol. Quote Link to comment Share on other sites More sharing options...
taylorblue5 Posted October 2, 2012 Author Share Posted October 2, 2012 Here's some pics and info from my 270mm rear disc conversion. Not the prettiest but working perfectly. Firstly i used zafira calipers, zafira h/brake cable, ford weld on caliper brackets and 270mm discs from a 4 stud vectra diesel. Only problem i had was when i realised the discs weren't 240mm which i had'nt bargained for. I just welded an extra 30mm onto the brackets and grinded the shape back. 1) Jack the rear end safely, i jacked up on the diff and placed axle stands. 2) With wheels removed let off the hand brake and set to work removing drums, I thoroughly recommend buying a slide hammer with hub puller, not expensive and a really useful piece of kit!! Use the hook attachment to hook over the leading edge of the drum and drift off. I was almost dissatisfied at how easy easy they came off as i was enjoying using my slide hammer and having the right tool for the job for once! Nearly put the drum back on and pulled the handbrake on, haha. 3) Once the drum is clear you need to pull the halfshaft in order to get access to remove drum backplate, first remove the 4 nuts on the axle-halfshaft flange. Once loose i used my frog foot attachment on the slide hammer and pulled the shaft out, be careful not to loose the shims or bolting face when removing. Also it sounds stupid but mark up which side it came from, they are both the same but one may have been shimmed out more. 4) Due to the backplate being bolted between the halfshaft and axle flange it is necessary to keep he assembly correctly spaced out. Take a cutting disc and cut a square from the backplate the correct size, you cant really go wrong as you just need the flat area in the centre but include the bolt holes as these are obv needed to locate bolt up the spacer. 5) Clean up the area n grease up for future removal, replace the half shaft and bolt it up as tight as you can, if you do this then you will know its good and tight against the flange because the nuts will continue to loosen, i used a nylon mallet and a bit of timer to 'batter the shite oot it' 5) offer up and bolt the discs onto the hub flange like below. 6) Now the fun part, fire your new pads in the calipers and bolt up onto your weld on brackets and hang the lot off the disc I was advised to use compressed air to push the piston out and grip the disc, holding the lot in place and helpfully locating the lot in a natural position. Why use compressed air when u can put a cable tie round the handbrake mechanism doin the same job. This is where you mark where your goin to weld the brackets on, if i had more time and space i would have stripped it down and in a perfect world id have removed the axle aswell, i didn't I just scribed the general area and grinded up ready for welding. I carefully welded up the bracket on a high power setting, dont want to harm the axle end and up wonky. 7) once in place let off the handbrake and rotate the disc to make sure its sitting square and true. 8) plumb up the brake line, the Zafira calipers use banjo fittings so i bought a Goodrich set of braided hoses :-D 9) Time to sort the handbrake out. The Manta part is a long adjustable threaded round bar and the Zafira cable bracket isnt. I welded on a pair of washers to make the shape as below. 10) mount up the ends to the calipers and offer everything up. Next we need to make a bracket to hold the cable outers and hold everything to allow the handbrake to pull against the cable, acting on the calipers. I used angle iron to make a simple bracket and drilled holes to locate the cables and welded this in place on the trans tunnel as below. All complete. And will look great when all cleaned up properly behind a set of wheels. Like i said not the neatest but can always be stripped and redone. Passed its mot so thats all that counts. 1 Quote Link to comment Share on other sites More sharing options...
taylorblue5 Posted August 6, 2013 Author Share Posted August 6, 2013 Sorry folks, not updated my project thread for a while. Lots has changed in recent months, I got tired of the r1 bike carb set up as I couldnt rely on them enough and were starting to cause some issues. http://i1210.photobucket.com/albums/cc414/taylorblue5/20130609_163913.jpg I bought a c20let converted vectra sri and sharply put the engine in my manta, but first i had to set up my new industrial unit which is awesome! No more welding in the rain. http://i1210.photobucket.com/albums/cc414/taylorblue5/IMG-20130605-WA0000.jpg <a href=http://s1210.photobucket.com/albums/cc414/taylorblue5/?action=view¤t=20130620_175833.jpg target=_blank><img src=http://i1210.photobucket.com/albums/cc414/taylorblue5/20130620_175833.jpg border=0 alt=></a> Also bought a 3 phase lift which makes working on cars a pleasure. I fitted an rs500 front mounted intercooler with 3 inch pipework, had to cut out the bumper and front panel a bit but im very happy with the results. <a href=http://s1210.photobucket.com/albums/cc414/taylorblue5/?action=view¤t=20130621_191357-1.jpg target=_blank><img src=http://i1210.photobucket.com/albums/cc414/taylorblue5/20130621_191357-1.jpg border=0 alt=></a> http://i1210.photobucket.com/albums/cc414/taylorblue5/20130621_191406.jpg http://i1210.photobucket.com/albums/cc414/taylorblue5/20130621_193250.jpg The only option i had for the intake was to use a powercap from an xe and tap in the sensor. Not ideally im usin a standard intake doughnut as i cant find a suitable silicone reducer, so if anybody know where i could get one id be much oblidged. http://i1210.photobucket.com/albums/cc414/taylorblue5/20130702_211932.jpg http://i1210.photobucket.com/albums/cc414/taylorblue5/20130704_153805.jpg Also been busy turbocharging my best mates 1.6 crossflow!! http://i1210.photobucket.com/albums/cc414/taylorblue5/20130622_145617.jpg http://i1210.photobucket.com/albums/cc414/taylorblue5/20130621_214540-1.jpg http://i1210.photobucket.com/albums/cc414/taylorblue5/20130621_214531-1.jpg Quote Link to comment Share on other sites More sharing options...
taylorblue5 Posted August 6, 2013 Author Share Posted August 6, 2013 <a href=http://s1210.photobucket.com/albums/cc414/taylorblue5/?action=view¤t=20130621_214531-1.jpg target=_blank><img src=http://i1210.photobucket.com/albums/cc414/taylorblue5/20130621_214531-1.jpg border=0 alt=></a> Quote Link to comment Share on other sites More sharing options...
taylorblue5 Posted August 6, 2013 Author Share Posted August 6, 2013 Quote Link to comment Share on other sites More sharing options...
taylorblue5 Posted August 6, 2013 Author Share Posted August 6, 2013 Bloody photobucket links. Sorry folks. Quote Link to comment Share on other sites More sharing options...
taylorblue5 Posted August 6, 2013 Author Share Posted August 6, 2013 Bit of fun with photoshop with other peoples cars here from when i was at sea. Just wanted to know what big wheels would look like etc hope nobody minds. Then i wanted to know what my old hatch d691jec would look like with a coupe back end so did this lol. Quote Link to comment Share on other sites More sharing options...
taylorblue5 Posted August 6, 2013 Author Share Posted August 6, 2013 Quote Link to comment Share on other sites More sharing options...
taylorblue5 Posted August 6, 2013 Author Share Posted August 6, 2013 More recent pics. New motorbike. Love it. Quote Link to comment Share on other sites More sharing options...
blitzi Posted August 6, 2013 Share Posted August 6, 2013 c ool well done scott!! Quote Link to comment Share on other sites More sharing options...
taylorblue5 Posted October 10, 2013 Author Share Posted October 10, 2013 Few pics of a Manta actually being outside and being hammered :-D Quote Link to comment Share on other sites More sharing options...
taylorblue5 Posted October 10, 2013 Author Share Posted October 10, 2013 Lsd needed though. 1 Quote Link to comment Share on other sites More sharing options...
spiney_norman Posted October 10, 2013 Share Posted October 10, 2013 If you're driving it on roads that wet, then I'd have to agree! Quote Link to comment Share on other sites More sharing options...
Kevin Abbott Posted October 11, 2013 Share Posted October 11, 2013 Looks very nice indeed :-) Quote Link to comment Share on other sites More sharing options...
opelscott22 Posted October 12, 2013 Share Posted October 12, 2013 Your car is looking really good! Youve put some mega effort into this, seeing yours out and about is good motivation to get on with my own! Scott. Quote Link to comment Share on other sites More sharing options...
taylorblue5 Posted October 15, 2013 Author Share Posted October 15, 2013 Thanks Gents. Its by no means a mint car just now but I'm happy that it is in a stable condition and cant deteriorate again like it did before. Over the winter i plan to rebuild my c20let and tidy my engine bay. I need a new 4 slot and plan to do rear arches, so I'm thinking I may as well buy a 400 body kit as this would sort the arches 4 slot also. The only part of the car that worries me is the roof as the repairs have risen, very annoying as its the only thing i don't feel confident doing it myself. The cars well loved but if i had my time over i probably wouldn't have taken it on as it was a huuuuuge undertaking, but now i am fully tooled up and have my industrial unit it has given me the boost i needed. Quote Link to comment Share on other sites More sharing options...
Kevin Abbott Posted October 16, 2013 Share Posted October 16, 2013 Can you sort the roof by putting in a bigger sunroof or is the rot further back than that in the classic manta achilles problem? I put a calibra one into the Mancona and other people in here have done some great conversions using Clio ones I think. Or if you 400 kit it do a full roof replacement. UPK did one the same as mine and took some great pics. It's ok if you take your time. Quote Link to comment Share on other sites More sharing options...
taylorblue5 Posted October 16, 2013 Author Share Posted October 16, 2013 The rot is down the left side behind the sunroof n infront of the rear screen. Is it hard to chop pillars and replace with a full section? I really cant be bothered drilling out spot welds and seperating stuff if im honest. Quote Link to comment Share on other sites More sharing options...
Kevin Abbott Posted October 16, 2013 Share Posted October 16, 2013 The problem is the foam they originally built the car with. They put foam between the sunroof tray and the roof so you need to take out the headlining and get all the foam out from between the two skins. Then you can repair the steel or replace the sunroof tray altogether On my 16v manta I removed the foam and welded in good steel. That solved the problem. On my wife's exclusive coupe I totally removed ALL the foam ( pain in the ar&e ) using scrapers,used hack saw blades and wire wheels. ( took a day ). Rust treatment and zinc painted. That roof never ever got any rust on it from then. That sunroof panel went on to going into another car. Quote Link to comment Share on other sites More sharing options...
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