CIH Turbo EFI by RallyBob

[RallyBob]

Yup, this is the one.....

[pvcar]

maybe u could put toghter a parts list on what is needed and part numbers of the diffrent things i would be interested on maybe building a setup for my gt.

[RallyBob]

Won't fit a GT, the manifold doesn't even come close. I thought about trying to put the turbo under the intake manifold, but if it wouldn't fit a Manta, there's no way it'll fit a GT.

Cost? $4600 in parts so far, plus about $2500 worth of my time. But I'm going to make a basic component list for Carlisle for posting on the car's window in a few weeks. But I'm not putting a part number list together, that would take about 10 pages to outline, I had to order parts from 8 different companies!

[Gary]

Yup, this is the one.....

There's the "Best in Show" winner.

[RallyBob]

maybe u could put toghter a parts list on what is needed and part numbers of the diffrent things i would be interested on maybe building a setup for my gt.

Since the GT setup would have to be fully custom too, but still different than the Manta, I won't delve into fabrication specifics.

A crude layout:
>Stock WRX turbo, ported turbine
>Stock WRX intercooler, modified to fit Manta
>Stock Opel EFI intake manifold, slightly modified
>Stock Nissan SR20 throttle body, underside modified for fast idle air bypass
>Suzuki motorcycle clutch cable for throttle cable, custom fitted
>Bosch 0-280-150-036 injectors, 380 cc's, 2.5 ohm resistance
>Custom fuel rail
>Aeromotive fuel pressure regulator
>Adapted Griffin radiator, electric fan
>4.75" x 13" Setrab oil cooler, remote oil filter, oil thermostat
>Russel twist-lock fuel and oil lines
>Samco sport silicone coolant hoses with custom aluminum connectors
>2.5" stainless steel downpipe
>Turbo header: all custom made flanges, 1.25" weldable cast steel pipe elbows used to fabricate runners
>Custom made 2" intercooler tubes with silicone connectors
>Compufire DIS-IX ignition with recurved distributor
>SDS EM-4D fuel injection. Optional fuel pump relay, 2-bar MAP sensor (allows up to 14.7 psi boost), fast idle solenoid, and resistors to drive Bosch injectors.
>Turbosmart boost controller
>Surge tank for cooling system
>Re-engineered crankcase breather system
>80 amp alternator
>Custom built heavy duty clutch
>Steel oil pan with turbo drain-back tube welded in
>Custom sealed cold air box and remote filter

As you can see, most of these items are custom, so they'd have to be built for your application, and my specs would not apply.

After working on this project for a few weeks, I've rethought the engine I'd like to build for my father's GT, and rather than build a N/A 2.7 litre, I think I'll go with a 2.6 litre turbo EFI engine instead. So if you can wait a year or two, I'll have specs on building that particular engine for a GT. I know it'll have a ball-bearing GT28RS turbo....that's as specific as I've figured the project out!

Bob

[pvcar]

well im not going to be doing this modification to my gt in the near future but i just like to plan things out and work everything befor starting and look at all my options maybe ill wait and see how that engine turns out your talking about, thanks for posting the parts list there i was just wondering what everything was that u have used on this turbo mod. cant wait to see it finished wont be able to see it at carsile though.

[RallyBob]

No chance to update yesterday's progress last night, I was at my friend's chrome shop late dropping off the parts to be plated. While I was there, I decided to polish a bunch of aluminum parts....boy I forgot how dirty and grimy that work was! Props to my friend Dan at Allied Metal Finishing for promising a quick turnaround and allowing me access to his buffing machines.

www.alliedmetalfinishing.com

[RallyBob]

Closeup of the turbo compressor housing after polishing and buffing.

[RallyBob]

And here's the surge tank/expansion tank after polishing and buffing.

[RallyBob]

BTW, this is where it all happens. My little corner at work where I build everything. More specifically, everything I fabricated during this project was made on the metal workbench in the centre of the photo. I can't wait to have a real shop someday....

[madhatterpdc]

I can't wait to have a real shop someday....

Is anyone else pondering exactly what kind of blessed Opelness would roll out of a *real* shop, if the above is indicative of what is coming out of a "fake" shop?

[Old Hippie]

I second madhatterpdc! What I've seen in this thread is due to a true "Opel artist". Hat's off to you, Bob. Even with 20 years in the KS. Air Guard Fab shop, you have a talent to envy. :o

[Paul]

I think Bob got out of the Opel business too soon. I think with the help of the advertising capabilites of this (and other) site, he would have had an excellent forum in which to sell his "Artwork"!

Paul

[RallyBob]

Thanks guys, glad to see my work is appreciated.

Paul, as much as I'd love to make a living doing this sort of work on Opels, you have to admit there is a very limited client base out there willing to spend the kind of money I'd have to charge for this type of work. It simply takes a lot of time, and I can't charge $20 and hour and still pay the bills. If I build a workshop and open a business again, the overhead will be high. I'd have to charge at least $75 per hour. And as of today I have 63 hours into the Carlisle turbo project....

I'm trapped within my own automotive passions, had I decided to work on
Porsches or Ferraris instead I could probably charge whatever I wanted and have a 2 year backlog. But with Opels most people are just trying to keep them running for minimal investment....few are looking to spend 10k under the hood of a car they might have paid $1000 for.

I'm in the minority I think, I just ordered 2 more Opel roller cams tonight...I should be seeing a shrink!

I like my daily driver WRX, but I can't bring myself to spend any money on it. It just doesn't 'do it' for me like an Opel does. I've been trying for 20 years to find another car that has as much soul as an Opel, and as much driver feedback, but have yet to come close.

Bob

[Gary]

Amen, Bob!!! This is one of the best "How To" articles I have seen. Thanks for sharing it with all of Opeldom!
(What is it with this marque that makes it so addicting?)

[GTJIM]

(What is it with this marque that makes it so addicting?)

I take it that is a rhetorical question!

The neat people that own them helps a bit .......

[namba209 (R.I.P.)]

Actually Jim, I think the people that own them is what makes the Marque. In that the cars are UNIQUE.

Ron

[Sander]

Yup, this is the one.....

Hi Bob, I'm fascinated by this thread. You're doing a great job. But I have one comment: Get rid of those hidious bumpers on this manta and get some european style bumpers!! If I had them I would give them to you

[RallyBob]

Well, the bumpers will be changed at some point, I talked the car owner into converting them last year. However there's no time to do that between now and Carlisle.

One nice thing about the '74 and '75 bumpers is the fact that they actually function as bumpers. The early bumpers are destroyed in a 3 mph tap, and it usually takes out the bodywork with it....

I'll be making some tubular subframes to slide into the OEM telescoping mounts, and the smaller early bumpers ('71, '72, not the '73 style with rubber trim) will be fitted over the tubing for aesthetics. The bumpers we have for this car are brand-new NOS parts, but old Opel chrome is isn't very good, I compared the NOS bumper chrome to some new parts plated at my friend's shop and the NOS parts looked yellow by comparison. So they'll get replated before installing them.

Last thing will be a new hood made from aluminized carbon fiber. It has a silver reflective quality to it which should look cool on a silver car, plus I think the darker hood will lend a 'Rallye' look to the car. But there's no way I have the time to make a mold and vacuum-bag a new hood before Carlisle....

Bob

[RallyBob]

Sorry, no 'cool' fabrications to report today. I basically scrubbed an old gas tank down clean in preparation to convert it to 'EFI compatible'.

I used paint stripper to remove all the undercoating and paint overspray, than cleaned the residue off with lacquer thinner.