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Retro Power

Supercharged Ascona 400R

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Well this project has been a little while in the making.

 

When we built Curt's White Ascona 400 replica we were introduced to his mate Jason who he had known for many years, and who also had a rhd 2 door ascona tucked away in cumbria. Jason asked whether we could do a similar build but with more of a track focus and more power.......of course we said yes!!

 

Here's what Jason dropped off with us:

 

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Rust in all the usual places:

 

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Oh no, the usual roof butchery!!

 

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So time to get started, strip it all down, wheel it into the blasting room and show it the blaster!

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Here it is awaiting its fate after underseal removal:

 

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and following a little attention with the crushed glass:

 

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So, time to start putting some new metal in!

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Not much of the front end was any good, so that was completely removed and replaced:

 

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You'll have to pardon the quality of some of the pictures, we've upgraded cameras a few times since these were taken. We now all have our own cameras in the workshop, which are all drop and waterproof and upload wirelessly so we have live updates on work!

 

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Enough to give a flavour of the work involved. Obviously there were a huge number of small bits that needed attention, but pictures of small repairs get a bit boring!!

 

Anyway, time to re-blast all the new metalwork to key it up and start the body prep and kit fitting!

 

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On with the Raptor underneath:

 

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Primer:

 

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And painted! We have a bit of a lack of photos at the painted stage but before assembly!

 

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Then onto the massive job of building the car. There are so many tasks and so many pictures that its hard to know where to start!

 

The entire engine installation is effectively a prototype as I don't know of anybody else that has done this with an M90 supercharger and proper chargecooler (which is essential for the setup to make decent power)

 

There are very few Opel parts in the build, and even fewer that are not modified in some way or other.

 

Lets start with the wiring loom, you'll have to bear with me in terms of other things in the pictures, as these are not in the order that work was actually completed!

 

The opel loom was raided for a few plugs such as those on the rear lights etc and then thrown where it belongs - in the bin!

 

After listing up what wiring is needed, for what assembly and in what location, the basic loom is created ready to be clad in flexible waterproof heatshrink with waterproof sealer at all junctions:

 

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Every wire is labelled at both ends and clear heat shrunk over the labels

 

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Routing within the car then commences:

 

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Then onto controls: here are a few examples of the pedal and steering setup:

 

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Looking at the dash in the pic above seems like a decent place to show a few of making that up!

 

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Time to flock it - handy having our own setup!

 

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and a panel for the clock console:

 

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I suppose some pictures of the engine and gearbox won't go amiss!

 

The gearbox is a Getrag 265 direct top, needs a bit of work to nicely mate with the XE:

 

Plate milled out:

 

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Concentric thrust cylinder mount fitted to Ford type 9 to XE 7 degree bellhousing:

 

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And all fits!

 

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Special starter setup to give us clearance for big blower:

 

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Fabricating Inlet/chargecooler manifold:

 

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That makes it look easy! The inlet has a core from a jaguar XJR6 in it fed by water from a seperate cooling circuit.

 

Fuel feed assembly made up and fitted in boot:

 

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gearbox x-member made up:

 

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Oil cooler and chargecooler radiators mounted and piped:

 

10670144_356584821178130_893436146044835

 

work on chargecooler pipes starts:

 

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Looking neat and tidy:

 

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Oil cooler circuit done, and tensioner for blower belt fitted to O/S engine/blower mount assembly:

 

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Filler housing for chargecooler circuit

 

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Throttle body housing fabricated and trial fitted, now you can see why we needed the special starter!

 

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all just fits, you'd think it might have been designed like that!

 

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complete blower assembly:

 

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Custom crank pulley drawn on CAD, cnc machined and anodised, drives blower and alternator (small vee belt behind the big blower one)

 

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bit tight on coolant pipes etc but it fits:

 

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gearbox and prop crossmemembers finished and plated, ready to fit with custom prop to go from the getrag 265 to the 4ha axle

 

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Exhaust fabrication time!

 

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Making up a centre console:

 

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Will do a little section on the build of the actual engine, another big chunk of hours on this!

 

Acid dipped block in primer, old oil and water pumps used to mask off:

 

1506994_232711166898830_1892677166_n.jpg

 

Block painted in super tough polyurethane anti corrosion paint:

 

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Block bored, honed and decked then cleaned and new core plugs fitted, ready to start assembly:

 

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acid dipping leaves the block like new inside and out:

 

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assembling steel rods and forged pistons after measuring everything and gapping rings etc:

 

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final double check with plastigauge before installing rods:

 

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stretch gauging ARP bolts for correct installation tension:

 

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Bottom end with modified MLS headgasket awaiting cylinder head:

 

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cylinder head stripped, chemical decarbonised, bead blasted, hot washed, new guides, seats recut, skimmed, final hotwash and ready to assemble:

 

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cylinder head assembly time, built a stand as I seem to be doing lots of these!

 

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Coming together:

 

 

 

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Edited by Retro Power
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Bit more fabrication work now on the supercharger mount which doubles as engine mount:

 

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with BMW aux belt tensioner fitted:

 

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Then need to fabricate the blower air intake/throttle body holder:

 

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boring head lol

 

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my alloy tig welding is improving!!

 

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Fabricating inlet:

 

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As you can see, "bunging a supercharger on it" has become fairly involved!

 

A turbo would be much easier, but that wasn't the name of the game here!

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Beautiful fabrication, having seen this in the flesh I can testify it's a work of art

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Yeah wow...just wow.

 

Makes my Manta build 'powered by eBay' look pretty crap!

 

Awesome work

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Its like Britains got talent with cars. :lol: That's a big fat yes from me. :thumbup phenomenal craftsmanship.

Edited by evo3000
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U lads are gifted that's some work of art keep the pctures coming

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The engernering and attention to detail is astounding and you guys should stand back and be proud of what you have achived so far because it is amazing. keep up the good work. will be good to see the finnished product.

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