CIH Turbo EFI by RallyBob

[RallyBob]

Originally Posted by tekenaar Where and what type of fuel pickup/check valves did you buy? . . . for future reference.

They're made by Walbro, I got mine from
http://www.autoperformanceengineering.com/
They were $15 each. Thanks to Travis for finding their website for me. If you go to 'external' pumps and look under accessories, they're listed.

[RallyBob]

The new Sparco shift knob came in today. I will still have to cut down the shifter extension once fitted to the car.

[RallyBob]

It was like Christmas today, I got all the parts back fom the plater.

[RallyBob]

I also got the parts back from Swain Technology today, the thermal barrier coating is awesome. Eventually the turbo downpipe will get this coating too, but since that part isn't even made yet, it will have to wait until after Carlisle.
This stuff will reduce the radiant heat by about 300 degrees, which is damn critical on a turbo engine due ot the extreme heat generated. It also retains the heat energy within the exhaust pipe, allowing the turbo to spool up faster.

[kmon]

The coated bits sure came back nice! Bob, I was curious why you went with swan tech over jet hot coatings...any particular reason? I like the look of the sterling finish jet hot offers, is it not as effective at removing heat?

[GTJIM]

"RallyBob Steals the Show!"

Working his magic on a little known Import Car, an Opel Manta, with exemplary fabrication skills a Connecticut officianado has stolen the show!

[RallyBob]

It's been my experience that all other coatings are mostly for appearance-sake. The Swain coating is a true aerospace coating, and Jet-Hot, HPC, and Airborn, no matter how pretty, just don't hold a candle to the Swain for heat-retention.

[RallyBob]

To be honest, after a sincere assessment of the work remaining, I don't think it will be done for Carlisle. Mr Murphy has deemed that everything takes 3 times longer than originally anticipated.....

Regardless, as I said before, I will at least try to have it together for appearance's sake and tow it to the show if necessary. But will it be ready to run? Not looking good for that right now.

[samdog]

Hey Rally Bob ...we have faith that if it can be done you can do it. The person recieving this piece of art is ....I'm not sure , but this is a special prodject. ......Samdog

[jordan]

wow! those parts look awesome, what kind of bill came with the chrome and the thermal barrier coating?

[RallyBob]

Originally Posted by jordan wow! those parts look awesome, what kind of bill came with the chrome and the thermal barrier coating?

It was $247 for the turbine housing and manifold....that's $150 for the manifold, $75 for the turbine housing, and just under $22 for shipping.

Don't know about the chrome prices, he hasn't billed me yet....


It's looking worse this morning as far as a completion date is concerned. I finally tore the engine down, and it has issues. Scratched cylinder walls, piston/valve interference, signs of coolant freezing at one point, etc. With only two weeks remaining, it ain't gonna happen....

[RallyBob]

Game over. Engine requires freshening up. So I'm pulling the plug on the Carlisle show as of today. Maybe now I'll get some sleep. *sigh*

Bob

[Travis]

Bob,

Any chance of getting the car done by calling in a favor from Dennis? I know for certain that Dennis thinks very highly of you and I'd expect him to queeze in any needed motor work...

-Travis

[Gary]

Well Bob, Opels on the Lawn is June 20. So rest for the weekend and then get back to work!

J/K.... That is an amazing effort.

[RallyBob]

Travis, there's more to it than machine work, I need some parts too. One of them is the ring set for a set of Euro 2.0 pistons. I will have them made by Total Seal rather than trying to locate them elsewhere (although Hastings lists them in their US catalog), the current rings show signs of damage from dirt entering the engine as some of the chrome is flaking from the top ring. I also need to re-notch pistons, replace springs/retainers, check the block and head to see if they're warped, hone the block, hot-tank all parts, geta new water pump and order a set of solid lifters from Gil.

Gary, you read my mind, I will have the car ready for Opel on the Lawn instead. And it will be better since there will be more time to do the detail work I wouldn't have been able to complete otherwise. I will also be able to make a proper stainless 2.5" exhaust for it, and maybe I will have removed the stock WRX turbo and replaced it with an IHI VF22, so it may be making closer to 300 hp than 220 hp by then. I can get some good dyno time in for evaluation, and can perhaps shake it down at an autocross???

Bob

[samdog]

Hey Rally Bob,, I think the vf22 is an excellent idea..more horses and less heat. I realize many people were looking forward to seeing this amazing prodject completed but things always take more time than expected...so I know that my 2.5 wagon with the roller cam, roller rockers and a few other little goodies will be an interesting substitute. I will be living proof that roller cam/ roller rocker motors are serious.

[Gary]

Don't forget.... there is an autocross ar Carlisle on Sunday.

[garrymc]

Originally Posted by RallyBob Game over. Engine requires freshening up. So I'm pulling the plug on the Carlisle show as of today. Maybe now I'll get some sleep. *sigh* Bob

Could you post your steps for freshening up the turbo engine? I know many of us will enjoy watching that. Thanks.

Garry

[RallyBob]

It's just basic overhaul procedures, nothing that hasn't been covered here before in these forums. I'm only going to document the fabrication aspect of this project.

[RallyBob]

Originally Posted by samdog .so I know that my 2.5 wagon with the roller cam, roller rockers and a few other little goodies will be an interesting substitute. I will be living proof that roller cam/ roller rocker motors are serious.

So Gary, during Carlisle should we raffle off hell-rides in Gregg's 2.5 litre roller-cam wagon? The thing just pulls plain silly at high rpms, you tend to forget you're driving an Opel....

Unfortunately I think it won't hook up at all now, he just pulled the LSD rear axle out of the wagon and put it into the Manta awaiting the turbo engine. Wheelspin at 50 mph anyone?

[tekenaar]

Originally Posted by RallyBob Got a very cool new tool today, it's a tubing bead former. I needed to add beads to the intercooler pipes and the coolant tubes so the silicone hoses I'm using won't blow off under pressure. Takes about 30 seconds to make a perfectly formed .050" tall bead. Very sweet.

Where, how much . . . you can e-mail me off-thread.

You had mentioned an upgraded "stock" clutch replacement, not the usual German HD unit or the S-10, in one of your posts that I can't locate now. Mind repeating the info? Thanks

[tekenaar]

Originally Posted by RallyBob Very little to report on. I'm basically burned out from this project, I'm literally falling asleep standing up. Hopefully tomorrow will be better. Just need to catch up on some sleep I think. Anyway, got a chance to go to my machinist's shop and glass bead an old flywheel I had laying around, then had him resurface it. It was previously lightened and balanced, and it now weighs 15.5 lbs. I'll be using a heavy duty pressure plate (30% stiffer) with a semi-metallic friction material on the disc. This is substantially stronger than the factory Sachs 2.0 litre HD clutches I used to use, but also costs less. Had it built by Action Clutch Exchange in L.A., they do nice work at a reasonable cost.

Found it, but need some detail from Bob on the clutch . . . $, where to get, contact info, anything needed to duplicate clutch pressure plate/disk combo. Thanks

[RallyBob]

Originally Posted by tekenaar Found it, but need some detail from Bob on the clutch . . . $, where to get, contact info, anything needed to duplicate clutch pressure plate/disk combo. Thanks

You'll have to check for current pricing. They essentially have 6 disc options, the first 4 options are with sprung-center hubs, with either semi-metallic (my choice), kevlar, combination kevlar/semi-metallic (basically the same as the Centerforce dual friction), or a sintered bronze friction surface. The other options are a 3 puck or 6 puck solid center disc (NOT recommended for any street use). Ask for the 30% stiffer resprung pressure plate. That's about it.

Phone number is (323) 269-6051, it's called Action Clutch Exchange, they're in LA.

If you'll look back through the archives, Travis posted pictures of one of these clutches which he bought from them, and which he uses in his E-Prepared Solo GT. The semi-metallic disc is very streetable, I've only had them chatter once when in stop-and-go traffic for a long time and it got hot, but once it cooled it was fine again. Kevlar lasts forever, but does not grip nearly as well. Sintered bronze is only for the brave of heart.....

[Travis]

Here's a couple links. I think I paid around $210 for the disc and re-sprung(30% stiffer) pressure plate. Well worth the money...

http://www.opelgt.com/forums/showpos...8&postcount=38
http://www.opelgt.com/forums/showpos...0&postcount=40

-Travis

[davegt27]

www.clutchnet.com


my invoice says i paid $173 back 2001 for a racing 6 button

davegt27