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Thread: 24v Ascona Wagon Upgrade

  1. #41
    Site Founder My location Gary's Avatar
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    First cut is the deepest!
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  3. #42
    Site Founder My location Gary's Avatar
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    Shifter location could get interesting!!!
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  4. #43
    Your Noble Friend ;-) My location G.v.Mainberg's Avatar
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    Quote Originally Posted by Gary View Post
    First cut is the deepest!
    Gary,

    are you sure you had it underneath the car the right way when you mocked up the cuts? I don't want your Wagon to go backwards once it's done!

    Dieter

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  6. #44
    Site Founder My location Gary's Avatar
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    Quote Originally Posted by heimue View Post
    Gary,

    are you sure you had it underneath the car the right way when you mocked up the cuts? I don't want your Wagon to go backwards once it's done!

    Dieter
    You mean it is not front wheel drive?
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  7. #45
    Site Founder My location Gary's Avatar
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    Progress!
    Steps: Measure, measure cut... Measure cut... Screw it, just cut!
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  8. #46
    Site Founder My location Gary's Avatar
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    More Progress

    The front suspension is in and the motor is resting on the front mounts. So I was able to get some accurate dimensions for the driveshaft, shifter, engine height, etc.

    It is ~23 inches from the Guibo joint to the torque tube. The '90 Senator driveshaft is a 2 piece unit with a center support. There is a spline at the center support that will take care of any lateral movement so the front shaft will need to be shortened and the piece from the rear u-joint will be mated to a cutdown Ascona d-shaft.

    The shifter mounting holes are right at the e-brake handle so it is going to be tight. Everything clears the e-brake, but I might have to shorten the e-brake handle. The R-25 is similar to a Getrag shifter

    The motor is sitting higher than I would like. I built up the motor mount brackets to clear the steering shaft and now the motor ends up just below the hood's bottom. So it will be rev.3 for the motor mounts to lower and clear the steering shaft. There is plenty of oil pan to crossmember clearance. The sway bar was eliminated so there was no interference at the rear of the motor. I was using Chevy poly tranny mounts for motor mounts.

    Clutch/brake pedal assembly will fit with minor mods to the battery box area. (The battery will be moved to the rear) The clutch master cylinder is attached to the pedal arm so it stays inside the drivers compartment.
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  9. #47
    Site Founder My location Gary's Avatar
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    Motor Mounts

    Revision 3 of the motor mounts consists of a 8" x 5", 1/4" plate bolted to the block at the stock bracket location and holes drilled in the front part of the plate match the mount bracket holes. This puts three quarters of the Chevy trans mount I am using as a motor mount over the mount bracket on the crossmember with one inch fan blade clearance.

    Most of the weight will now be on the crossmember and the block will be around 1 inch lower from the rev. 2 brackets.

    Pics to follow.
    Last edited by Gary; 12-30-2013 at 10:42 PM. Reason: Revised plate size
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  10. #48
    Site Founder My location Gary's Avatar
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    Yeah! The flat head socket cap screws I ordered from McMaster-Carr will be here tomorrow! Mount bracket work will continue over the holiday.
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  11. #49
    Site Founder My location Gary's Avatar
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    Here are some pics of the engine bracket plate, crossmember to mount adapter plate, assembled motor mount, and the rear tranny mount. The last pic shows how much the sway bar would have interfered with the oil pan.

    Just need to make two engine bracket plates and that will complete the 'easy' stuff!
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  12. #50
    Site Founder My location Gary's Avatar
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    Two detailed updates made to the Project Blog: 24V Ascona A Conversion

    Comments welcomed here and on the blog.
    Last edited by Gary; 01-02-2014 at 10:07 PM.
    My 24 Valve Ascona A wagon project blog.
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  13. #51
    Site Founder My location Gary's Avatar
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    Finished the mount bracket plates today and the motor and trans are in place.

    Next up is the clutch/brake pedal placement, then shorten the gear shifter. Sheet metal work will follow.

    Single digit temps tonight and over a foot of snow predicted by Friday night. Below zero (f) tomorrow night. Glad that I have a heater in the garage!
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  14. #52
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    Very nice project Gary...very nice!

  15. #53
    Site Founder My location Gary's Avatar
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    Motor Mounts

    Here are the mount bracket plates installed. The drivers side was trimmed for knock sensor access.
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  16. #54
    Site Founder My location Gary's Avatar
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    Ordered a 7 inch booster/master cylinder combo. The stock booster would not fit and one from a 1990 Senator was too large. While waiting for that I started on the 5-speed shifter.

    The shifter location caused a little concern as the stock location put it back near the base of the emergency brake handle. The linkage is very similar to the Getrag 240 setup. I made 2 "C" shaped brackets for the trans to shift lever connection and cut down the shifter base as much as possible. It moved it forward enough (~6 inches) so it is now close to the tip of the e-brake handle.

    The shifter was in and out at least 10 times before the alignment was set and the brackets welded together. Final assembly will be as soon as the paint dries.

    If it is too far back once the seat is in place, I'll have to make into a short throw or get creative with the shift handle.

    I'll post pics later.
    My 24 Valve Ascona A wagon project blog.
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  17. #55
    Owner of EZ2Wire.com My location GoinManta's Avatar
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    Man that thing is tight.. in all the ways you can use that term..

    Did you take some lessons from the Manta Dennis did years ago..?

    Looks really good though.. How much heavier is it than the stock setup..?
    CURRENT
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  18. #56
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Quote Originally Posted by Gary View Post
    Ordered a 7 inch booster/master cylinder combo. The stock booster would not fit and one from a 1990 Senator was too large. While waiting for that I started on the 5-speed shifter.

    The shifter location caused a little concern as the stock location put it back near the base of the emergency brake handle. The linkage is very similar to the Getrag 240 setup. I made 2 "C" shaped brackets for the trans to shift lever connection and cut down the shifter base as much as possible. It moved it forward enough (~6 inches) so it is now close to the tip of the e-brake handle.

    The shifter was in and out at least 10 times before the alignment was set and the brackets welded together. Final assembly will be as soon as the paint dries.

    If it is too far back once the seat is in place, I'll have to make into a short throw or get creative with the shift handle.

    I'll post pics later.
    Gary, if you need ideas on the e-brake hsndle, I shortened the one on my rallycar, but retained the push-button release. A little bit of work but not too bad.
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    '70 GT 'Bonnie', '71 Ascona 4-dr turbo - winter beater, '71 Ascona 4-dr 'Turd' - rallycar, '72 Manta Rallye - hillclimb car, '72 Ascona wagon - 'Red', '72 Manta - caged street car, '73 Manta Luxus, '73 Ascona 2-dr, '74 Ascona 2-dr - Project X, '74 Manta Luxus - factory sunroof, '74 Manta ITB racecar, '75 Manta, '75 Sportwagon, '75 Manta - racecar

  19. #57
    Site Founder My location Gary's Avatar
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    Quote Originally Posted by GoinManta View Post
    Man that thing is tight.. in all the ways you can use that term..

    Did you take some lessons from the Manta Dennis did years ago..?

    Looks really good though.. How much heavier is it than the stock setup..?
    Dave Miller's Manta was part of my research, but ended up using very little from the work that Dennis did. (More room in a Manta's nose so the motor was not set back.)

    Not sure what the weight difference is. 2 extra cylinders, R-28 tranny is heavier, aluminum head, etc... Most of the weight is behind the front crossmember.

    Quote Originally Posted by RallyBob View Post
    Gary, if you need ideas on the e-brake handle, I shortened the one on my rallycar, but retained the push-button release. A little bit of work but not too bad.
    I was going to ask you for details on that Bob.
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  20. #58
    Opeler My location SpringGT's Avatar
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    Gary is it possible for you to relocate the e-brake handle location to the left side of the drivers seat like the Porsche 944? See picture.
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  21. #59
    Site Founder My location Gary's Avatar
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    Quote Originally Posted by SpringGT View Post
    Gary is it possible for you to relocate the e-brake handle location to the left side of the drivers seat like the Porsche 944? See picture.
    Anything is possible with this build.
    I think I can get away with shortening the handle. The e-brake housing clears the trans guibo. Here's a pic of the modified bracket and second gear location.

    That bend in the original was there for a reason. I had to shim the tower out to get 5th gear & reverse.

    UPS just dropped off my brake booster brackets!
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    Last edited by Gary; 01-09-2014 at 04:31 PM.
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  22. #60
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Quote Originally Posted by Gary View Post

    I was going to ask you for details on that Bob.
    These might help.
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    '70 GT 'Bonnie', '71 Ascona 4-dr turbo - winter beater, '71 Ascona 4-dr 'Turd' - rallycar, '72 Manta Rallye - hillclimb car, '72 Ascona wagon - 'Red', '72 Manta - caged street car, '73 Manta Luxus, '73 Ascona 2-dr, '74 Ascona 2-dr - Project X, '74 Manta Luxus - factory sunroof, '74 Manta ITB racecar, '75 Manta, '75 Sportwagon, '75 Manta - racecar

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