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Kevin Abbott

Manta Coupe. Cosworth Engine. Eps, 265, Hartges. Update July 2015

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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

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

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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 :'(

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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

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

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

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And lead fill

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Manta brakes, deathwish so m3 discs and integralle calipers

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RS500 intercooler tucked into nose

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cage added

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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

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Then I added EPS

Corsa b column

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Remove the outer collapsable top part of the corsa bit

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You are left with

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

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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

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Take your manta column and remove the inside part

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

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

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Edited by Kevin Abbott
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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

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After a little googling I found out the RS500 Touring cars used a Getrag box, the 265 :rolleyes:

I have a couple lying around so what the hell.

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265 monza box, yea :D

Need to join the two

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Ali adaptor ( cheers Cliff )

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Cut big hole in T5 bellhousing

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10 hours of measuring and measuring and measuring and swarf everywhere

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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

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

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It went a different colour

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Info, Sierra cosworth spigot bearing outer is 21mm, inner 14mm

Manta outer 21mm, inner 15mm

I needed a 21OD, 12ID

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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

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Bolted up

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Edited by Kevin Abbott

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

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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

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That part slips over the inner of the corsa bit

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These two parts will be welded together

Make room to get at the bolts

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

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Bottom part of the column

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

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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

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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

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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

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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

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So after a plug on one hole

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And a weld then grind flat

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The 5x120 can be drilled

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

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It did this

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Studs in and ready for the wheels

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

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

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Sorry Peter, i sold the rebuilt ZF I had on it.

Engine mounts are done,

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Other side harder to see as I had to use a cosworth 4x4 oil filter extension

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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?

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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.

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Car is now home again :rolleyes:

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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.

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Rad crossmember to be replaced with a new one ( thank's Robbie)

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Horrible tunnel to be cut out and replaced with a manta one

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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

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Under seat mount rail to be changed

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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?

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One of the 3 different sets of wheels i need to choose from, rev 16x9

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Nice kit

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So jobs at weekend are to remove rad crossmember and start removing the lead from the rear quarter and completely remove that

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its nice to have a shell in ur garage to tinker with:) this is gunna be awesome!

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looking good kev .how many 400s will there be in the north west .when we all get are fingers working :D:lol:B)

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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 B)

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Inside too

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Car up onto it's bread tray movers

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This one has to come off so it's off with its lead

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I'm cutting carefully and in sections as I only have one spare rear quarter!

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Looking for spot welds on the window surround

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Door pillar ones hard to find

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Rear panel edge needs tidying up

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This is a tricky bit as it has about 3 different places where the rear quarter joins to it

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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?

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Edited by Kevin Abbott

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i would not remove the b post part , i would cut out the 2 rectangular holes for the window hinges . hope that sounds right ..

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Beer and mantas in the garage, a combination made in heaven

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Getting the rest of the quarter off I needed access where the spot weld cutter won't reach so I use this

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I made a speed controller from a 500w dimmer as I hate using these dangerous things on full

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A tricky area

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Rear quarter removed and cleaned up the mounting areas

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New panel thrown at it and it stuck

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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 :D

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looking good, lot of good work on this project, going to be brilliant when its done, keep up the good work

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good work kev, almost a shame ur gunna cut the arch off for the kit:-)

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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

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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

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