CIH Turbo EFI by RallyBob
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Thread: CIH Turbo EFI by RallyBob

  1. #1
    Project 1450 supporter... Site Supporter My location RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob's Avatar
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    CIH Turbo EFI by RallyBob

    I don't know how I let myself get talked into these things...

    7 weeks 'til Carlisle. I have to fabricate an entire turbo system for a CIH Opel, have parts coated and plated, tear-down and regasket an existing engine, install the engine, and dyno-tune it.
    We'll see if I even come close.

    So, the baseline engine is a Euro 2.0 block with a ported 1.9 head with big valves. I also need to install a smaller cam for use with the turbo (less overlap). I was originally going to use the stock L-Jetronic with larger injectors and a rising-rate pressure regulator, but since that entire system is basically 'stupid' I felt that a stand-alone ECU was the only way to go

    Here's what I had to start with:
    Attached Images
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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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  3. #2
    Project 1450 supporter... Site Supporter My location RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob's Avatar
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    This mess is the stock fuel rail from a 2.0 EFI system. Too much clutter, too small injectors, and just plain ugly.
    Attached Images
    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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    Project 1450 supporter... Site Supporter My location RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob's Avatar
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    I stripped the intake down, and rough-polished it smooth with various sanding rolls and and an orbital sander. It'll be sent out to the chrome shop next week with some other parts.
    Attached Images
    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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    Project 1450 supporter... Site Supporter My location RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob's Avatar
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    The new fuel rail I made is made from 3/4" DOM steel tubing. I brazed pieces of flared 5/16" tubing that I cut from the stock fuel rail...these fit into the hose ends of the injectors. Yet to be welded onto the fuel rail in these photos are the AN fittings at the ends for the fuel line inlet and the Aeromotive adjustable pressure regulator.

    The injectors are blue Bosch '036' injectors, which flow around 380 cc's at 44 psi. More than enough for the horsepower goals of this engine.
    Attached Images
    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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    Project 1450 supporter... Site Supporter My location RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob's Avatar
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    The turbocharger I'm using is a stock Subaru WRX TD04 unit. Good enough for 227 hp in a Subaru at 14 psi boost. They're plenty cheap and available, as a lot of WRX owners upgrade to a larger turbo. I see them on Ebay for $100-$200 all the time.

    I polished the outside of the turbine smooth in preparation for ceramic coating, and ported the turbine inlet.
    Attached Images
    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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    Project 1450 supporter... Site Supporter My location RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob's Avatar
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    I started to make the header flange for the turbo manifold. I'm using 3/8" mild steel for the flange with 1.25" cast steel pipe elbows to make the runners. It will be TIG welded together then ceramic coated. It's a lot of work making a flange from scratch...
    Attached Images
    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

  8. #7
    Old Opeler My location GTJIM will become famous soon enough GTJIM's Avatar
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    Laser Cutting

    Bob,

    I took a correctly sized drawing of the rear disc brake brackets I needed, to a local engineering shop that had a laser cutting set-up.

    Before my startled eyes they cut out the brackets in a few minutes - bolt holes and all!

    Modern technology has its place.
    GTJim
    Opel Owner since last Century!

    Copyright 2000-2009
    J D Henry
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    Cunning Linguist Site Supporter My location tekenaar will become famous soon enough tekenaar's Avatar
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    Re: Quest for Carlisle

    Originally posted by RallyBob
    I don't know how I let myself get talked into these things...

    . . .

    . . .

    Here's what I had to start with:
    So, WHO was able to talk you into this, Bob? Project must have been at least SOMEWHAT interesting to you then, right?


    1960: '61 Rekord PII 1.7 3S 3.9 '69 Kadett LS 'sprint' 1.9 3A 3.18
    1970: '70 GT 1.9 4S 3.44 '72 GT 2.2SSD 5S 3.44 '72 GT 2.4FI 5S 3.44P
    1970: '73 GT 1.9FI 4S 3.44 '75 1900 1.9FI 4S 3.44
    1980: '85 Bitter SC 3.9FI 5S 3.44P
    2000: '09 Solstice GXP Coupe 2.0 SIDI VVT "Stage 2" Turbo 5S 3.73P


    "De inimico non tantum loquaris male, sed cogites."

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    Project 1450 supporter... Site Supporter My location RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob's Avatar
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    Re: Laser Cutting

    Originally posted by GTJIM
    Bob,

    I took a correctly sized drawing of the rear disc brake brackets I needed, to a local engineering shop that had a laser cutting set-up.

    Before my startled eyes they cut out the brackets in a few minutes - bolt holes and all!

    Modern technology has its place.
    Hah! Not here my friend.....

    I've had Opel parts made for years including parts that were made via CNC plasma cutter, CNC laser cutter, and CNC water jet. But none of them would look at me for quantities less than 20 pieces, and preferably 50+ pieces. One-offs don't make them any money, therefore they either price it out of sight, or outright refuse to do it. Welcome to America!
    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

  11. #10
    Project 1450 supporter... Site Supporter My location RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob's Avatar
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    Re: Re: Quest for Carlisle

    Originally posted by tekenaar
    So, WHO was able to talk you into this, Bob? Project must have been at least SOMEWHAT interesting to you then, right?
    My good friend Gregg coerced me into trying to build this. It was originally supposed to be just an engine swap prior to Carlisle, but the turbo thing grew out of it.

    Why? HP is always interesting...
    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

  12. #11
    Have Opel, Will Travel oldopelguy is on a distinguished road oldopelguy's Avatar
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    Quest for Carlisle

    Originally posted by RallyBob
    My good friend Gregg coerced me into trying to build this
    More like "Gregg got a good look at the parts for another turbo project I had laying around and just had to have one for himself." I know how these things really work, Bob. Wonder what kind of cam he'll be using.....
    Last edited by oldopelguy; 03-29-2004 at 12:15 AM.
    1958 Rekord Sedan, 1958 Olympia Wagon, 1959 Opel Olympia Sedan, 1967 Kadett Coupe, 1967 Admiral Sedan 4L CIH-6, 1968 Kadett fastback 1.1L, 1970 Kadett Wagon Turbo 2.2L, 1971 Kadett Sedan 1.1L, 1975 Manta Wagon 4.3L V-6

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    Site Admin My location Gary will become famous soon enough Gary will become famous soon enough Gary's Avatar
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    Rolling, Rolling, Rolling, keep those Opels Rolling.....

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    Like the fuel rail, and the plenum is going to be purdy chromed, nice work bob. Please more pics as it comes along

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    Project 1450 supporter... Site Supporter My location RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob's Avatar
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    Re: Quest for Carlisle

    Originally posted by oldopelguy
    More like "Gregg got a good look at the parts for another turbo project I had laying around and just had to have one for himself." I know how these things really work, Bob. Wonder what kind of cam he'll be using.....
    I'm actually 'de-camming' the current engine by a lot....replacing it with a mild hydraulic cam. .441" lift and 214 degree duration @ .050", with wide 112 degree lobe separation. You'll barely notice it now. No roller cam. Roller rockers of course though.

    Bob

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    Member My location Stressed Stressed's Avatar
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    So Bob,

    How much does a dream like this cost? Could the owner be heavily involved to learn? I con only dream of this type of project. When it comes to paint, upholstery, or audio, I'm the man, but I usually make things worse when I touch mechanical.

    Stressed
    I don't expect you know what an Opel GT is, but I need some parts.

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    Cunning Linguist Site Supporter My location tekenaar will become famous soon enough tekenaar's Avatar
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    Originally posted by Stressed
    So Bob,

    How much does a dream like this cost? Could the owner be heavily involved to learn? I con only dream of this type of project. When it comes to paint, upholstery, or audio, I'm the man, but I usually make things worse when I touch mechanical.

    Stressed
    You and I need to talk . . . not that I can't do those things, it's just that the "mechanicals" do SO MUCH more for me.


    1960: '61 Rekord PII 1.7 3S 3.9 '69 Kadett LS 'sprint' 1.9 3A 3.18
    1970: '70 GT 1.9 4S 3.44 '72 GT 2.2SSD 5S 3.44 '72 GT 2.4FI 5S 3.44P
    1970: '73 GT 1.9FI 4S 3.44 '75 1900 1.9FI 4S 3.44
    1980: '85 Bitter SC 3.9FI 5S 3.44P
    2000: '09 Solstice GXP Coupe 2.0 SIDI VVT "Stage 2" Turbo 5S 3.73P


    "De inimico non tantum loquaris male, sed cogites."

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    Member My location Stressed Stressed's Avatar
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    Sounds good. Unfortunately, I am also cash strapped, and while I believe the cash situation will soon streighten itself out, it will probibly entail a move from the area.
    I don't expect you know what an Opel GT is, but I need some parts.

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    I will like to see how the hood will lash down after the intake is placed. I would like to do this to my GT but will have to relocate AC compressor.

    Ken
    73 GT AC (as seen on Car and Driver TV), "74 Rallye AC now lives with Dieter,'75 Sport Wagon AC,Auto 181,000 now lives at Gene's house.

  20. #19
    Project 1450 supporter... Site Supporter My location RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob's Avatar
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    Originally posted by Stressed
    So Bob,

    How much does a dream like this cost? Could the owner be heavily involved to learn? I con only dream of this type of project. When it comes to paint, upholstery, or audio, I'm the man, but I usually make things worse when I touch mechanical.

    Stressed
    I will likely have a total parts cost next week, as this week I will have everything ordered that I need for the project. There are still a few loose items that will need attending too afterwards I'm sure....there are always last minute incidentals.

    Add to this the 'spit and polish' which of course costs more....ceramic coatings, chrome, powder-coating, and then the labor to fabricate.

    I work for $50 an hour when it comes to fabrication. At least in this state, that's dirt cheap. Car dealers and repair shops get $65-$72 an hour here, and they aren't building parts, they're just swapping them. Last week I put 17 hours into this project, and that was after my day job. And I didn't work over the weekend....

    Bob
    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

  21. #20
    Project 1450 supporter... Site Supporter My location RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob has a spectacular aura about RallyBob's Avatar
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    Originally posted by opelblitz
    I will like to see how the hood will lash down after the intake is placed. I would like to do this to my GT but will have to relocate AC compressor.

    Ken
    The project car is a 1975 Manta, so no hood mods are needed. But the turbo manifold I'm building will never fit into a GT, there's just not enough room.

    Bob
    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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