"LeMons" Opel Manta turbo system, now slated for street use. - Page 5
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Thread: "LeMons" Opel Manta turbo system, now slated for street use.

  1. #81
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    Quote Originally Posted by RallyBob View Post
    The oil dam installed in the rear drain hole of the head. This helps to keep the rear cam lobes, notoriously prone to failure from lack of pressurized oil, oiled via splash lubrication. I also added a small hole drilled in the side of the oil dam to allow oil to drain back from the head to the oil pan when the engine is shut off. Otherwise dirty oil would remain during an oil change.
    How come oil dam will not let oil drain between day to day start-ups,but old dirty oil will go down to oil pan?

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  3. #82
    Senior Member My location anastosmotors's Avatar
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    Even though this cam is pretty small, I set the valve lash on the loose end. I went with .016" intake, and .018" exhaust. My reasoning is that under boost the EGT's will get pretty hot, and the valves will expand more than usual. I don't want to hang the valves open under those circumstances from too small a valve clearance.

    Is the valves expand or the stock rocker arms ? I can not get it. I adjust valves .018" intake and .020" exhaust with stock rocker arms and about .014" INT and .016" EX and they are noisy (race car)
    Pete
    Last edited by RallyBob; 09-17-2014 at 11:23 AM. Reason: Fixed quotes
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  4. #83
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Quote Originally Posted by anastosmotors View Post
    Is the valves expand or the stock rocker arms ? I can not get it. I adjust valves .018" intake and .020" exhaust with stock rocker arms and about .014" INT and .016" EX and they are noisy (race car)
    Pete
    It's the valves mostly. The heads of the valves get hot from combustion temps and the heat is transferred to the valve stems. The valves get longer as they heat up.

    Yes, Opels tend to have noisy valve trains. Especially with a big camshaft, there's a lot of valve clearance. That's the nature of the design.
    Last edited by RallyBob; 09-17-2014 at 12:29 PM.
    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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  6. #84
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Quote Originally Posted by Lesis View Post
    How come oil dam will not let oil drain between day to day start-ups,but old dirty oil will go down to oil pan?
    It will drain overnight. But while the engine is running, there will be a reserve of oil at the back of the head.
    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

  7. #85
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    Cam Oiler Drain Dam

    http://www.opelgt.com/forums/6a-engi...html#post53814

    Modified common plumbing fitting:
    3/8" by 1/2" copper reducer.

    Opel GT Source Oil Dam Part 6087.
    Mounts in oil return hole in back of cylinder head.

  8. #86
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Today pretty much wrapped up the 'engine assembly' part of this project. Here I've fitted the rear main seal to the engine.




    Here I've fitted the oil pan for the final time, using a one-piece all rubber gasket purchased from Dieter and a group buy here on the forums. It fit together nicely, and I used Ultra Grey gasket maker between the gasket and the block/timing cover, then fitted the pan itself dry to the gasket.




    I also threaded on an oil filter, and put on the alternator belt.




    Here you can see the -10AN (5/8") drain line from the crankcase breather, draining back into the oil pan. I used an Oetiker clamp at the top, and a 90° AN fitting at the pan. I had to bend the dipstick slightly forward for access.

    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

  9. #87
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Looking for a starter for this engine, I saw no need to steal one off another engine or use one of my 'good' 2.4 starters. Those are for longer stroke engines or high compression engines, of which this is neither. In my barn stash I found an in-the-box SR57X starter, which is simply a Bosch factory rebuilt Opel starter. It had some patina as my barn is pretty damp at times, but a bench test showed it worked perfectly. So I started wire wheeling the light rust that was on the nose cone of the starter, and while wiping it with an acetone-dampened rag, I found the black paint came right off. I ended up getting it pretty much spotless in 10-15 minutes.




    Then a little coat of primer:




    Followed by a few coats of Rustoleum gloss grey enamel, because black starters are so cliché...






    So what remains?

    On the engine, just the thermostat itself, and the rear freeze plug (I have no access until the engine comes off the stand).

    For the entire project, I need to fabricate the 3" exhaust (I have all the components, but it needs to be done in a car), I need to build a throttle linkage, and rebuild the Weber 45 DCOE. That's about it.

    Tonight I dusted off my engine test stand project and found all my notes and drawings. I needed to see how far I am along in that project, and I will probably continue working on that on Friday.
    Last edited by RallyBob; 09-17-2014 at 10:15 PM.
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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. #88
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    Is this green motor going into the red wagon? Very green motor.

  11. #89
    7,000 Post Club My location wrench459's Avatar
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    Quote Originally Posted by RallyBob View Post
    ..


    F'in sweet!
    and not because of the paint on the starter!

    Si vis pacem, para bellum "If you want peace, prepare for war"

  12. #90
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Quote Originally Posted by samdog View Post
    Is this green motor going into the red wagon? Very green motor.
    Yes. Odd combo I admit.
    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

  13. #91
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    Starter bolts?

    Followed by a few coats of Rustoleum gloss grey enamel, because black starters are so cliché...

    Hi Bob- those starter bolts sure look trick with their 15 mm Hex heads...
    Last edited by RallyBob; 09-19-2014 at 01:02 AM. Reason: Fixed quote

  14. #92
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Quote Originally Posted by bello View Post
    Hi Bob- those starter bolts sure look trick with their 15 mm Hex heads...
    Yup, thanks again for those Ernie!

    I actually forgot I had them until last week. Found them in a baggie while looking for some other parts.

    It's not such a big deal with the smaller 2.4 starters, but with the 1.9 starter the smaller bolt heads really have a lot more clearance. Works great with my 15 mm swivel socket.
    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

  15. #93
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    r u going to fit the rear starter motor bracket or do you think its overkill

  16. #94
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Quote Originally Posted by nickincrete View Post
    r u going to fit the rear starter motor bracket or do you think its overkill
    I don't think it's overkill. I was going to put the bracket back on, but I couldn't find one! I just make sure the mounting bolts are good and tight. If anything, I'll miss the bracket as a good solid ground for the starter body, as the battery ground cable attaches to the same spot.
    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

  17. #95
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    I got my throttle linkage figured out. I ended up killing two birds with one stone so to speak, I made part of the linkage also work as a stabilizer for the carburetor. I wasn't happy with the silicone coupler as the only mounting method for the carburetor. My added brace takes some of the load off the coupler.

    A piece of .105" thick steel bolts to the top of the Weber carb body using existing screw holes. The linkage uses a stock Manta throttle bellcrank, modified with some oilite bushings at the pivot point. Don't mind the extra long bolts, they were just used for mockup. I need to buy appropriately sized hardware still.




    This piece of 1/2" tubing is welded to the linkage bracket, and then bolts to an existing hole on the turbo's CHRA to support the DCOE Weber.




    I used some thick walled stainless tubing as standoffs on the thermostat housing. I countersunk the bolt holes slightly with a unibit.




    The cable attachment was completed using some bar stock, and a section of a stock Manta throttle bracket welded together. Simple, but it works. The bellcrank motion is transfered to the DCOE via a pair of small spherical rod ends I had laying around. They're from Pratt and Whitney aircraft, although they're 30+ years old. I got them with a set of 40 DCOE's that were on an Opel GT. That car owner was an engineer at Pratt and raided the parts bins for his throttle linkage...lol. I haven't figured the best place to run a return spring yet however.

    Here's the throttle closed:



    And here's WOT:
    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

  18. #96
    Tennessean Site Supporter My location hrcollinsjr's Avatar
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    Quote Originally Posted by RallyBob View Post
    I don't think it's overkill. I was going to put the bracket back on, but I couldn't find one! I just make sure the mounting bolts are good and tight. If anything, I'll miss the bracket as a good solid ground for the starter body, as the battery ground cable attaches to the same spot.
    Is there a bracket available for the 2.4 starter?

    Harold

  19. #97
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Quote Originally Posted by hrcollinsjr View Post
    Is there a bracket available for the 2.4 starter?

    Harold
    If there is, I've never seen one. Seeing how the 2.4 starter is literally half the weight of a 1.9 starter, and shorter to boot, I doubt they ever fitted one.
    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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    Moderator Site Supporter neuropel's Avatar
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    Quote Originally Posted by RallyBob View Post
    Here I've fitted the oil pan for the final time, using a one-piece all rubber gasket purchased from Dieter and a group buy here on the forums. It fit together nicely, and I used Ultra Grey gasket maker between the gasket and the block/timing cover, then fitted the pan itself dry to the gasket.

    Interesting... So we still need to "schmutz" these new one-piece gaskets between the block and the gasket to prevent leaks? I'm installing one shortly as well. Lots of great photos and info in this thread Bob, as usual!
    Paddle faster...I hear banjo music!
    ________________
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    1974 Manta GT/E 2.0 LHU
    1973 Manta Rallye 2.5L
    1967 Kadett L Rallye 1.1L

  21. #99
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    Quote Originally Posted by neuropel View Post
    Interesting... So we still need to "schmutz" these new one-piece gaskets between the block and the gasket to prevent leaks? I'm installing one shortly as well. Lots of great photos and info in this thread Bob, as usual!
    I did just to make sure it sealed well.

    Also worth noting: I trimmed the pan rail section of the gasket where it fits into the timing cover. It's a bit wide and kept popping out. The actual square section which fit into the timing cover fits fine. Just the pan rail section is a tad bit wide.
    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

  22. #100
    Project 1450 supporter... Site Supporter My location RallyBob's Avatar
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    With the 45 DCOE I had planned on using requiring too many (expensive) parts, I decided instead to freshen up an old 40 DCOE Weber I had laying around. It's an older Italian made DCOE which tend to be better built that the newer ones. It even has a brass throttle shaft instead of a steel one.

    This carb proved to be in good shape, but it had a bit of white powdery corrosion from moisture and the float adjustment was way out to lunch. Still, with nothing more than a $25 gasket kit, some vapor blasting, some paint, and some work on the wire wheel it cleaned up really nicely.

    The only thing I have left to do carb-related is to make a custom air filter housing with integral air horns.







    Last edited by RallyBob; 11-24-2014 at 12:58 PM.
    wrench459 and nickincrete like this.
    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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