"LeMons" Opel Manta turbo system, now slated for street use. - Page 2
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Thread: "LeMons" Opel Manta turbo system, now slated for street use.

  1. #21
    Tennessean Site Supporter My location hrcollinsjr's Avatar
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    Quote Originally Posted by bello View Post
    Hi Bob- I've seen this before- somewhere in 1972 they dropped the dowel pin and added the shouldered bolt with the same OD as the old dowel pin- ... I don't really know everything- I first read about this in a Service Bulletin that is now over 40 years old!!! Ernie Bello
    I've probably seen two myself and the bulletin.

    Harold

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  3. #22
    Opel Key Master My location opelspyder's Avatar
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    I have a couple of those necked down bolts, I thought they were for air conditioning brackets or something of the such, and that was why I had them
    Check out our Opel restorations at
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  4. #23
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Today I bolted some of the shiny bits together. I still can't finish the engine itself until I get the head back from the machine shop. So shiny bits it is....

    Turbo exhaust manifold bolted up to a head for mockup purposes.



    Misc parts that are going together, ceramic thread locker, hardware.




    Intake manifold and Audi wastegate bolted in place.



    Last edited by RallyBob; 05-25-2014 at 09:45 PM.
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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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  6. #24
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Turbo CHRA and compressor housing bolted up, silicone coupler fitted to intake.








    DCOE Weber intake manifold fitted with silicon coupler. There WILL be a metal brace added to support the weight of the Weber DCOE hanging off the front of the turbo. I don't trust just the silicone hose!





    After all this, all that remains is to port/assemble/install the head, design the throttle linkage, build a 3" exhaust, and rebuild the Weber carb.
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    E.G. Sauer 2/26/66 - 2/18/10. Rest in peace big guy...

    '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

  7. #25
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Dissected my donor Weber 45 DCOE (it was in the trunk of a car I got years ago) and figured out what I need to make it work. It's missing one of the 3.5 auxiliary venturis, and both main venturis. I've decided I'm going to fit 38 mm venturis in there. I also need the retainer tabs for the air horns, and a few more small bits and pieces, but I should have enough spares from other gutted DCOE's to put it all together.

    I also had a tall K & N air filter and housing I'll be using, which again was a spare part I had laying around. I simply shined up the housing a bit and washed the filter element.



    Last edited by RallyBob; 06-03-2014 at 09:25 PM. Reason: spelling
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    E.G. Sauer 2/26/66 - 2/18/10. Rest in peace big guy...

    '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

  8. #26
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Today I picked up my cylinder head from the machine shop. This is going to be a pretty basic big valve head, not unlike the writeup I did here on the forums a few years ago. This is essentially my early 1990's-spec street big valve head. Since it's not a race head and budget was important I left the OEM cam bearings in the head as they were in excellent shape. I also left the original rocker studs in the head.

    Pretty much all the shop did was magnaflux the head, install bronze valve guides, install hardened steel exhaust seats, cut the seats for bigger valves (1.72" intake and 1.50" exhaust valves from a small block Chevy), and cut the spring seats to work with my seals and springs. They also milled the head flat, as it was pitted from the rust corrosion, and it was "cupped" between cylinders #2 and #3, typical when a head is overheated.




    Here's one of the chambers as I got it back...freshly cut seats, hardened exhaust seats, and bronze guides. I previously unshrouded the chambers before I sent the head to the shop.



    And here is the same combustion chamber after I did a little bit of bowl work to the exhaust port. Nothing crazy, but typically the flow goes from 67 cfm to 95 cfm with these minor mods on a 1.9 exhaust port. They are almost TOO easy to get to flow well. The intakes are another story....




    I also attacked the outside of the head with a wire wheel, just to remove the surface rust and the residual paint.



    My Flickr photos.
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    E.G. Sauer 2/26/66 - 2/18/10. Rest in peace big guy...

    '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

  9. #27
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    This is from last week but I forgot to post the pics. I put my turbo mockup on the engine test stand shortblock. Added the valve cover too. Starting to look like an engine now!




    Viny Charb, ggl and marto like this.
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    C.R.L. 9/22/69 - 12/8/99, J.M.L. 3/3/43 - 6/15/04, D.M.L. 9/19/50 - 6/23/10
    E.G. Sauer 2/26/66 - 2/18/10. Rest in peace big guy...

    '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

  10. #28
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    I got the exhaust ports all ported between last night and today. A little more porting on #1 and 4, a little bit less on #2 and 3. Just to try to achieve flow balance.

    I *was* going to do my basic street porting on the intake ports, but damn if I didn't get carried away and started doing one of my "double apple" racing porting jobs. Guess I've gotta make them all that way now? Sure, I won't see the same benefit with the 1.72" valves compared to the 1.85" valves, but it should be worth another 5 cfm per intake port anyway. Usually around 117 cfm instead of 112 cfm. Oh darn.

    My elbow is gonna hate me tomorrow!
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    Last edited by RallyBob; 06-09-2014 at 01:36 PM. Reason: grammar
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    E.G. Sauer 2/26/66 - 2/18/10. Rest in peace big guy...

    '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

  11. #29
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Had a marathon porting session. I'm a hurting unit, but I got about 70% of the intake ports done. I'll pay for it tomorrow!!
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    E.G. Sauer 2/26/66 - 2/18/10. Rest in peace big guy...

    '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

  12. #30
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Quote Originally Posted by MikeNotigan View Post
    Curious as to the compression ratio you will be running with the carb set up. Most excellent engineering going on here; I wish you the best in running her!
    Mike, since today my hands are useless thanks to my marathon porting session yesterday, I decided to instead calculate my compression ratio. Here are the
    numbers I measured out.

    Combustion chamber volume: 51.2 cc's
    Compressed Victor Reinz gasket thickness: 5.344 cc's
    Swept cylinder volume: 474.144 cc's
    Piston dish volume: 13.8 cc's
    Ring land volume: .90 cc
    Compression height volume (piston above deck): (-1.208 cc)

    Total volume at TDC: 70.036 cc's
    Total volume at BDC: 544.180 cc's

    Calculated compression ratio is 7.77:1.

    The head has been milled .010" and the chambers unshrouded, but the bigger valves reduce the volume a bit. Block is also milled .010". I fitted NGK BPR7HS plugs which are one heat range colder than stock.
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    E.G. Sauer 2/26/66 - 2/18/10. Rest in peace big guy...

    '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

  13. #31
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    A week later I'm a little bit healed. Got the intake ports finished in terms of porting. Still gotta polish them however. Probably another 3-4 hours for me these days.
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    E.G. Sauer 2/26/66 - 2/18/10. Rest in peace big guy...

    '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

  14. #32
    ggl
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    Quote Originally Posted by RallyBob View Post
    A week later I'm a little bit healed. Got the intake ports finished in terms of porting. Still gotta polish them however. Probably another 3-4 hours for me these days.
    Too bad I live across the pond or I'd give you a hand with the finishing work. I may not be very good at porting but I'm getting pretty decent at make them look good, who said you can't polish a turd ?

    I assume you'd provide beer .....

    Looks nice Bob, too bad it won't see any competition use
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    Is that a Triumph head?
    1970 GT - Why can't I find any of my nuts.

  16. #34
    ggl
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    Quote Originally Posted by Team Unter Puff View Post
    Is that a Triumph head?
    Yeah, don't have any Opel projects right now so it was the only thing I had to show off a bit and see if I could get a job at RB's shop .....
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  17. #35
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    Quote Originally Posted by ggl View Post
    Too bad I live across the pond or I'd give you a hand with the finishing work. I may not be very good at porting but I'm getting pretty decent at make them look good, who said you can't polish a turd ?

    I assume you'd provide beer
    Now I'm sure if you had said "I will bring the beer" you would have been hired.
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  18. #36
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    I ended up grinding all the ports lightly with a finer toothed carbide to smooth things out before polishing. Less sanding dust for me to breathe in, and fewer sanding rolls wasted.
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    C.R.L. 9/22/69 - 12/8/99, J.M.L. 3/3/43 - 6/15/04, D.M.L. 9/19/50 - 6/23/10
    E.G. Sauer 2/26/66 - 2/18/10. Rest in peace big guy...

    '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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    You truly are inspiring. Craftmanship that everyone of DIYselfers wanted to come close.

    Would love to see hp/Nm numbers and video with it running when done.
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    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Quote Originally Posted by Lesis View Post
    You truly are inspiring. Craftmanship that everyone of DIYselfers wanted to come close.

    Would love to see hp/Nm numbers and video with it running when done.
    Yea, well, I fear I'll have a finished engine but no car to put it into at this point.
    My Flickr photos.
    C.R.L. 9/22/69 - 12/8/99, J.M.L. 3/3/43 - 6/15/04, D.M.L. 9/19/50 - 6/23/10
    E.G. Sauer 2/26/66 - 2/18/10. Rest in peace big guy...

    '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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    Lemons manta

    Well the car is here,need the ascona motor back after three years so we can have lift and shop space to finish the f--ing thing.Come on Bob

  22. #40
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Quote Originally Posted by itb gt View Post
    Well the car is here,need the ascona motor back after three years so we can have lift and shop space to finish the f--ing thing.Come on Bob
    Yea, yea. , easier said than done when it's coming out of my pocket!
    My Flickr photos.
    C.R.L. 9/22/69 - 12/8/99, J.M.L. 3/3/43 - 6/15/04, D.M.L. 9/19/50 - 6/23/10
    E.G. Sauer 2/26/66 - 2/18/10. Rest in peace big guy...

    '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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