Kevin Abbott Posted January 22, 2012 Share Posted January 22, 2012 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 3 Quote Link to comment Share on other sites More sharing options...
Kevin Abbott Posted January 22, 2012 Author Share Posted January 22, 2012 (edited) 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 February 15, 2012 by Kevin Abbott Quote Link to comment Share on other sites More sharing options...
johno Posted January 22, 2012 Share Posted January 22, 2012 VERY NICE PROJECT!! :) Quote Link to comment Share on other sites More sharing options...
robah Posted January 22, 2012 Share Posted January 22, 2012 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. 2 Quote Link to comment Share on other sites More sharing options...
danko_f4 Posted February 14, 2012 Share Posted February 14, 2012 very nice car What is the rear diferencial Quote Link to comment Share on other sites More sharing options...
opelmantagsi Posted February 15, 2012 Share Posted February 15, 2012 great effort so far, looks awesome. whats the plan with the engine mounts? Quote Link to comment Share on other sites More sharing options...
peter evans Posted February 15, 2012 Share Posted February 15, 2012 hi kev its peter i bought the roof skin from you do you have a lsd for sale? thanks peter Quote Link to comment Share on other sites More sharing options...
Kevin Abbott Posted February 15, 2012 Author Share Posted February 15, 2012 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, Other side harder to see as I had to use a cosworth 4x4 oil filter extension Quote Link to comment Share on other sites More sharing options...
opelmantagsi Posted February 15, 2012 Share Posted February 15, 2012 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? Quote Link to comment Share on other sites More sharing options...
Danny D114BCW Posted February 15, 2012 Share Posted February 15, 2012 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. Quote Link to comment Share on other sites More sharing options...
Ivan1969 Posted February 16, 2012 Share Posted February 16, 2012 super Quote Link to comment Share on other sites More sharing options...
garymanc Posted February 17, 2012 Share Posted February 17, 2012 hi kev its peter i bought the roof skin from you do you have a lsd for sale? thanks peter http://totalopel.com/forum/showthread.php?t=17620 in ireland car is looking good kev,when will it be finished Quote Link to comment Share on other sites More sharing options...
Kevin Abbott Posted February 17, 2012 Author Share Posted February 17, 2012 http://totalopel.com...ead.php?t=17620 in ireland car is looking good kev,when will it be finished For Billing Quote Link to comment Share on other sites More sharing options...
mickappy Posted February 17, 2012 Share Posted February 17, 2012 which year kev;-). Quote Link to comment Share on other sites More sharing options...
Kevin Abbott Posted May 29, 2012 Author Share Posted May 29, 2012 Car is now home again Engine and box are out so i can look at replacing some of the parts i have changed to suit a different intercooler and rad. Rad crossmember to be replaced with a new one ( thank's Robbie) Horrible tunnel to be cut out and replaced with a manta one This rear quarter has to go, i was going to do an internal filler but now it's not allowed they say for a MOT so i have a new rear quarter to go on Under seat mount rail to be changed I have chucked the 400 kit at the car and it's ok but not as good as the Trevor Lewis 240 kit i sold, slight gaps but this can be sorted. I may have stored it with slight stress on the panels? One of the 3 different sets of wheels i need to choose from, rev 16x9 Nice kit So jobs at weekend are to remove rad crossmember and start removing the lead from the rear quarter and completely remove that Quote Link to comment Share on other sites More sharing options...
mickappy Posted May 30, 2012 Share Posted May 30, 2012 its nice to have a shell in ur garage to tinker with:) this is gunna be awesome! Quote Link to comment Share on other sites More sharing options...
bigcliff Posted May 30, 2012 Share Posted May 30, 2012 looking good kev .how many 400s will there be in the north west .when we all get are fingers working 1 Quote Link to comment Share on other sites More sharing options...
Kevin Abbott Posted June 2, 2012 Author Share Posted June 2, 2012 (edited) Power steering video test The motor needs turning 180 degree as in mickappys car Can't embed it so here's a link to click http://smg.photobuck...nt=7a692f15.mp4 Looking in the boot for the first time in a while and it's still mint Inside too Car up onto it's bread tray movers This one has to come off so it's off with its lead I'm cutting carefully and in sections as I only have one spare rear quarter! Looking for spot welds on the window surround Door pillar ones hard to find Rear panel edge needs tidying up This is a tricky bit as it has about 3 different places where the rear quarter joins to it Can anyone confirm if the fixed rear quarter cars ( as mine is going to be) have this infill piece in the rear window? Or do I remove it? Edited June 3, 2012 by Kevin Abbott Quote Link to comment Share on other sites More sharing options...
poddy Posted June 3, 2012 Share Posted June 3, 2012 i would not remove the b post part , i would cut out the 2 rectangular holes for the window hinges . hope that sounds right .. Quote Link to comment Share on other sites More sharing options...
Kevin Abbott Posted June 3, 2012 Author Share Posted June 3, 2012 Beer and mantas in the garage, a combination made in heaven Getting the rest of the quarter off I needed access where the spot weld cutter won't reach so I use this I made a speed controller from a 500w dimmer as I hate using these dangerous things on full A tricky area Rear quarter removed and cleaned up the mounting areas New panel thrown at it and it stuck Some fine tuning needs doing and a small rust repair at the inner bottom section of the 'b' post and it's out with the spot welder 2 Quote Link to comment Share on other sites More sharing options...
garymanc Posted June 3, 2012 Share Posted June 3, 2012 Quote Link to comment Share on other sites More sharing options...
opelmantagsi Posted June 4, 2012 Share Posted June 4, 2012 looking good, lot of good work on this project, going to be brilliant when its done, keep up the good work Quote Link to comment Share on other sites More sharing options...
mickappy Posted June 4, 2012 Share Posted June 4, 2012 good work kev, almost a shame ur gunna cut the arch off for the kit:-) Quote Link to comment Share on other sites More sharing options...
cdi200 Posted June 4, 2012 Share Posted June 4, 2012 Hey kev,,ecellent thread mate ,,have enjoyed reading it,,,ref the b post window hinge rubber grommet thingys,,,,theyll need to come out,,,,ive got fixed rear quarter windows,,,,i took them out and fibreglass filled the two holes in each b post,,,cheers the noo Quote Link to comment Share on other sites More sharing options...
Kevin Abbott Posted June 4, 2012 Author Share Posted June 4, 2012 good work kev, almost a shame ur gunna cut the arch off for the kit:-) Yep that's a 1000 Euro panel and i'll be chopping it up! Hey kev,,ecellent thread mate ,,have enjoyed reading it,,,ref the b post window hinge rubber grommet thingys,,,,theyll need to come out,,,,ive got fixed rear quarter windows,,,,i took them out and fibreglass filled the two holes in each b post,,,cheers the noo Thank's for the heads up about the holes, i'd forgotten they would need filling Quote Link to comment Share on other sites More sharing options...
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