Astra Redtop with a twist

[Paul]

Sorry to start the thread like this, but not interested in any 'it wont work comments etc', but positive criticism is more than welcome!

I know its not ground breaking cause its been done before, but not common at all, in fact I only know of one other Mk2 with this engine in it. So, a good friend of mine currently has his car in my workshop.

Its a Astra mk2 which had a 2.0 8V Turbo in it, this has now been ditched in exchange for a Saab Turbo engine.

So we came up with the idea on Thursday night last week, phoned around a few places and managed to source the whole lot for the sum of 150quid.

Its covered 96k so we thought we better have a quick check on the shells, which are all good (sorry no pics).

I also have no pics of us taking the engine out as it was rather hot today and we're all sunburnt from the weekend so just wanted to get it done asap! lol

Anyway, a few hours later we got back to the workshop with this:

http://img.photobucket.com/albums/v14/lashednova/Picture116.jpg

And we had to take this out of his car:

http://img.photobucket.com/albums/v14/lashednova/Picture050.jpg

And shes out:

http://img.photobucket.com/albums/v14/lashednova/Picture042.jpg

(incidently the 8V turbo manifold will be for sale soon, has a T3 flange on it)

http://img.photobucket.com/albums/v14/lashednova/Picture077.jpg

Next up was to change the gearboxes over, so off came the Saab one, and on went the Vaux item. After trying for around 15 mins we realised the tyre that the engine was sitting on was in the fecking way lol :

http://img.photobucket.com/albums/v14/lashednova/Picture082.jpg

An one Vauxhall gearbox on one Saab Engine:

http://img.photobucket.com/albums/v14/lashednova/Picture088.jpg

Note you have to grind this off so that yucan get a water hose on the pipe:

http://img.photobucket.com/albums/v14/lashednova/Picture114.jpg

We chose to use the Vauxhall gearbox so we can retain the standartd mountson it, and alsote standard drieshaft. Ideally the engine could do wth being closer the NS chassis leg, but this would make life moredifficult fr us in the fact that we would have to fabricate three mounts, fancy driveshafts and not be 100% sure that it was sitting straight and true.

So the new home for the engine:

http://img.photobucket.com/albums/v14/lashednova/Picture013.jpg

And underneath ready to be winched up:

http://img.photobucket.com/albums/v14/lashednova/Picture028.jpg

http://img.photobucket.com/albums/v14/lashednova/Picture081.jpg

We got the engine up into position and had no hope of even getting the NS front moun on, so back down in went, after a bit of measurement we decided what need to come of the OS chassis leg:

http://img.photobucket.com/albums/v14/lashednova/Picture038.jpg

http://img.photobucket.com/albums/v14/lashednova/Picture012.jpg

http://img.photobucket.com/albums/v14/lashednova/Picture086.jpg

[Paul]

And off:

http://img.photobucket.com/albums/v14/lashednova/Picture060.jpg

This is going to get strengthened up, having a good think about how before we go gung-ho! Also the lower X member on these is paper thin as they run wishbones, so that will be getting made into a 4"x2" box section to add some extra strength into the front end.

So back up went the engine, and with the two gearbox bolts lined up, its in:

http://img.photobucket.com/albums/v14/lashednova/Picture005.jpg

Fair bit of room at the back:

http://img.photobucket.com/albums/v14/lashednova/Picture036.jpg

Nice bit of OS clearance:

http://img.photobucket.com/albums/v14/lashednova/Picture035.jpg

http://img.photobucket.com/albums/v14/lashednova/Picture030.jpg

Few more pics:

http://img.photobucket.com/albums/v14/lashednova/Picture115.jpg

http://img.photobucket.com/albums/v14/lashednova/Picture094.jpg

Basically the Saab engines run a multigroove system with the water pump, alternator, air con and rather large tensioner all on the auxillary belt of the bottom pulley. We are going to see what are option are with making everything V groove, if that isnt possible then we will frount mount the alternator.

We are going to use a similar engine mount as to what the Saabs do which comes from the OS Suspension turret. And also see if we can make a mount from the OS lower corner to the new X member or chassis leg, depending on what room we have.

Other than that there doesnt really seem to be any inital problems! :eek:

So more to follow soon

Paul

[Rich]

Interesting, dont really get many problems with those engines either!

What happened with the 8v turbo?

[Plug]

was hoping to do this to my m8s mk3 ashtray but he cant afford the saab now lol.

Suscribed to this as its the next big thing in the world of vaux i think.

Are you going to be splicing the saab engine loom to the vaux loom or using a aftermarket ecu??

[napalm_27]

hmm interesting
will make a nice read
keep up the good work mate

[Twistie]

What happened with the 8v turbo?

??????

[xe Dan]

when i picked up the nova i saw the astra spoke to you mate he seemed very clued up was a nice bit of home turboing that 8v lump hope this goes well to

[saloonwoody]

my m8 put the 2.3 turbo into his mk3 gsi and he had to chop loads out but its in , dunno wot it goes like cos its not wired up yet lol

[Rickyb]

looks spot on and you have a p.m

[corsa-xe1]

looks good! that manifold was a rs turbo on with a 2.0 8v flange welded in!!

[Mazz]

cool conversion, what bhp are they standard?

[Ryan5cyl]

B204L is 185bhp as standard, same engine used in Per Eklunds 800bhp Pikes Peak 93 I think, same as in my car! (only not 800bhp :cry:)

[wizzy]

i thought the Saab turbo engine just bolted straight in with the same mounts as the c20xe :confused:

[Paul]

i thought the Saab turbo engine just bolted straight in with the same mounts as the c20xe :confused:

AFAIK, someone feel free to correct me if im wrong.

The subframe will bolt straight of a 9000 and straight onto a astra mk3/cally/cav, however the mk2's dont have subframes. So it will be a bit more Nova orientated and hopefully may be of some use to you lot?


cool conversion, what bhp are they standard?
Yep about 175 or so i think.

So been down to the breakers this morning to get intercooler + pipes, few spares coilpacks, ecu's etc. Think we now have everything we need except the turbo.

As for the 8V manifold for those of you that have PM'd me he wants 70 posted, the engine is sold. His name is Glenn and number is 07877941627.

Not sure when were next going to get down the yard to have another go at it, but in the mean time we'll be ordering a few new gaskets and cleaning, fun :( .

[brucer]

you dont mess around do you.lol. nice to see all that work done over a short period of time. get some more pics up once you do some more.

[dj_wudgey]

one for sloth here!! well good work lads keep it up!!

[Paul]

Had a hectic week and weekend, so a few more pics from today:

We decided we needed more clearance for the bottom pulley.

So we marked up the area that would be in the way:

http://img.photobucket.com/albums/v14/lashednova/IMG_0138.jpg

http://img.photobucket.com/albums/v14/lashednova/IMG_0139.jpg

http://img.photobucket.com/albums/v14/lashednova/IMG_0140.jpg

Out it came:

http://img.photobucket.com/albums/v14/lashednova/IMG_0141.jpg

http://img.photobucket.com/albums/v14/lashednova/IMG_0142.jpg

http://img.photobucket.com/albums/v14/lashednova/IMG_0143.jpg

To strengthen it back up, on went a 6mm plate:

http://img.photobucket.com/albums/v14/lashednova/IMG_0144.jpg

http://img.photobucket.com/albums/v14/lashednova/IMG_0145.jpg

http://img.photobucket.com/albums/v14/lashednova/IMG_0146.jpg

http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs114.snc1/4839_100197282399_637782399_2455727_971618_n.jpg

[Paul]

And behind the plate on went this 2x2" box section, welded from the turret along the plate and to the front of the plate. This enables us to retain full lock, and give us the extra clearance. Then we used some sheet steel to make it look pretty and although its only thin the shape of this should give even more strength:

http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs114.snc1/4839_100197862399_637782399_2455734_2173326_n.jpg

Then we used some sheet steel to make it look pretty and although its only thin the shape of this should give even more strength.

http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs114.snc1/4839_100198712399_637782399_2455736_4553305_n.jpg

And a few pics to show the clerance we now have:

http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs114.snc1/4839_100198952399_637782399_2455737_4322299_n.jpg

http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs114.snc1/4839_100199397399_637782399_2455740_2378994_n.jpg

http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs114.snc1/4839_100199962399_637782399_2455755_4501811_n.jpg

http://photos-h.ak.fbcdn.net/photos-ak-sf2p/v649/159/104/637782399/n637782399_2455775_5153175.jpg

http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs114.snc1/4839_100200842399_637782399_2455777_2167276_n.jpg

The alternator on these is mounted at the back, to retain this in the standard position, we would of have to cut out near enough most of the turret, so we have decided to front mount it. The Saab 9000 donor car, had one of its engine mounts from the drivers side suspension turret, we are going to retain the Saab mount which bolts to the block and fabricate the metal part of the mount which will be welded to our new chassis leg, the 2" box section, and around the top of the turret. We are still considering whether to fabricate a torsion bar style mount from the front of the gearbox to the lower X member, thoughts? We are removing the lower X member and replacing it with box section so that it stiffens the front up, and also a strut brace across the top in the standard postion to aid in strength also.

Tomorrow evening we are going to do a bit more to it, hopefully we will be able to have it all mounted in and the lower X member welded on.

Paul

[Plug]

some good progress there :thumb:

alot of chopping going on there nearly as bad as burgo lol

[Paul]

The alternator now has a new home:

http://photos-f.ak.fbcdn.net/photos-ak-sf2p/v649/159/104/637782399/n637782399_2497101_2263575.jpg

http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs106.snc1/4908_102569387399_637782399_2497102_4034118_n.jpg

http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs106.snc1/4908_102569487399_637782399_2497103_570045_n.jpg

Then we had a look at the X member yesterday:

http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs086.snc1/4908_102569557399_637782399_2497104_1024411_n.jpg

Its now all fully welded in, and gusseted on each side too.

Paul

[Nick J]

Some quick progress there Paul! Nice to see someone attempting something a little different. Your not shy with the grinder are you! lol

Nick.

[Sloth]

any more on this ?

[John]

top stuff fella! i'm guessing in won't remain standard? what's the rest of the car like?

[bai1ey]

top build i would love to have the now how to do this kinda thing dont suppose the full 2.0 8v turbo engine is for sale

[Pistol Pete]

Fast progress. Good job. Your not afraid to cut about your car are you!!!!

[Graeme]

Looking good so far Paul, I bet this is like hardcore porn to Sloth lol

[Paul]

erm, waiting on some new rods bolts, shells and the right turbo, they came with t25,t3 and td04, we bought the wrong one LMAO (serves us right for not checking)

Have an update soon with a bit fo luck.

[MattBrown]

Any news?

Running?

Whats it drive like?

[Paul]

its coming along, ill take more pics when i go back down the garage.

[srs1]

good progress here. as all ready said.

nice to see someone breaking the mould

[rwaggers]

nice work fella. good to see something different:thumb:

[Southie]

its coming along, ill take more pics when i go back down the garage.

Are you back from the garage it's been two days lol

I like it :cool:

[MattBrown]

good progress here. as all ready said.

nice to see someone breaking the mould

Not your usuall, it wont work? lol

[Plug]

any more updates on this
?

[Paul]

A bit of an update, to be honest quite a lot has been done, but too many pictures taken.

Our mate Kev broke Sipo's Astra Turbo a while ago, so a fair few parts from that have come Glens way. We changed the rear beam to a disc one from that. It now has the rainbow cream interior, the digidash from it, and got the spare bodykit off of sipo's car.

The plate for the front mount alternator was not substantial enough, and when the alternator was put under tension by the belt, it was causing the bracket to bend, and the alternator to sit on the piss. So we had to redo it. We used a nice big lump of 6mm plate, and mounted it where the power steering pump would sit. The Saab alternator was very meaty at the back, which made it sit too close to oil pump. So we had a scout round the scrappies for a slim multi groove alternator, and came up with a Micra jobbie. We grabbed the tensioner too. So now it has a proper tensioner (one where you just wind the bolt in/out) and it sits lovely.

We also had to replace the rod bolts, we didnt run into an problems with this.

We got a T3 turbo in exchange for out T25, complete with t25-t3 adaptor, downpipe, actuator. So thats now fitted, when we fitted it we also decided to make the downpipe, which now finishes just behind the sump.

We had a bit of a nightmare with the gears on this thing, when we dropped it back onto its wheels, and selected a gear the wheels didnt lock, and we couldnt understand why. The pressure plate was clamped tightly onto the flywheel and drew the fingers flat, the vauxhall friction plate was exactly the same thickness as the saab one (that was the only bit we changed, as the saab friction plate and less splines the vaux gearbox). So we took the gearbox back of and measured up the Saab flywheel to the Vauxhall flywheel, same thickness size etc, the bolt holes were offset different to the Vauxhall flywheel, so we decided that we definitely had to use the Saab one. So we drilled out the vauxhall pressure plate to fit the saab flywheel. So it now had a brand new clutch in, again the finger pulled up flat, we checked it again and stuck the box back on. Dropped it back on its wheels and again, no bloody gears! At this point it was looking as though the gearbox was knackered. We got under it to have a final check, and noticed that on the back edge of the Saab sump there is a lug which was stopping the OS Shaft from going completely in (doh!), ground it off and it worked exactly as it should...

We built the front end to fit around the Astra radiator, but when we went to put the radiator in, the pipe from the water pump to the radiator would have had to be the most funky thing you ever did see, so we decided it would have to be the Saab radiator. So we made the brackets up for that yesterday. A friend of ours was unlucky enough to drive through a big puddle recently and hydraulic his engine (starlet turbo), so thats being broken for bits, so Glen snatched the intercooler and boost pipes off of it. We got all that fitted yesterday too, and with some rather crude measurements, we managed to get it to sit pretty well in the front bumper.

The sump has got to be modified, the saab engine sits forward in the saab's and where we have straightened it up, it sits very low to the ground, and the oil pickup sits on the piss. So we are taking the lowest point out of it (under half a litre of oil we will loose), and going to modify the oil pickup to suit.

We had the oil cooler lines made up the other day and thats is now fitted, well attatched to the engine. lol

So some pics, i will get more detailed pics of what weve done in time...

http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs070.snc3/13742_206770437399_637782399_3537699_2914147_n.jpg

Custom headlight anyone?

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs070.snc3/13742_206766212399_637782399_3537691_1024912_n.jpg

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs070.snc3/13742_206763857399_637782399_3537684_867273_n.jpg

http://photos-a.ak.fbcdn.net/hphotos-ak-snc3/hs050.snc3/13742_206761272399_637782399_3537682_7564246_n.jpg

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs050.snc3/13742_206757702399_637782399_3537680_2008380_n.jpg

http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs070.snc3/13742_206752627399_637782399_3537673_1594863_n.jpg

Til next time

Paul

[Connor]

looking :cool:

[Balley]

Well done :D

[scott.parker]

Fook me, the poor car! lol

Looks like a right ballache of a job, fair play to you all, i would of kicked the **** out of it by now with all the hiccups, just a short patience i have..

Well done all..

Scott

[djbrowney]

looks good buddy

that rocker cover ****s me up every time lol lol lol

[Paul]

its alive, it runs but knocks, so maybe new engine time.

Its been painted too, pics to follow

[Paul]

Right, to bring this project up to date:

As I said it runs, it was proper knocking, but we've decided tonight that it is mechanically ok.

Compression test results:

Cylinder 1-220psi
Cylinder 2-225psi
Cylinder 3-225psi
Cylinder 4-225psi

When we took the plugs out to do the compression test, wedged in #3's plug was a lump of what appeared to be solder but was steel? No idea what it ws or how it got in there, but its out now, and its not knocking and banging. The lifters have quiened right down, and it sounds quite nice now actually!

Its ticking over well, revving hard, and seems to be fine, just got to tidy the wiring up, as it was all hard wired to the battery lol.

It has been painted, still needs to be flat+polished, pics are gun finish (bear in mind it was painted in my old dusty cold barn).

Primer:

http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs180.snc3/20780_309927817399_637782399_3935124_1277244_n.jpg

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs180.snc3/20780_309928592399_637782399_3935125_344885_n.jpg

Custom headlight, alignment is ok (we think lol)

http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs180.snc3/20780_309929572399_637782399_3935126_5759299_n.jpg

Painted:

http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs200.snc3/20780_309933097399_637782399_3935129_651301_n.jpg

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs200.snc3/20780_309944307399_637782399_3935279_2850687_n.jpg

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs180.snc3/20780_309945132399_637782399_3935282_5807875_n.jpg

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs180.snc3/20780_309947807399_637782399_3935296_8354491_n.jpg

http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs200.snc3/20780_309942882399_637782399_3935265_2008592_n.jpg

http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs200.snc3/20780_309940907399_637782399_3935258_8359275_n.jpg

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs200.snc3/20780_309934972399_637782399_3935197_855783_n.jpg

http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs180.snc3/20780_309933887399_637782399_3935130_7744957_n.jpg

http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs200.snc3/20780_309931542399_637782399_3935128_428497_n.jpg

http://photos-a.ak.fbcdn.net/hphotos-ak-snc3/hs180.snc3/20780_309930647399_637782399_3935127_2977799_n.jpg

Paul

[Adam]

Good work, paintwork looks well for diy jobbie!!

[Connor]

good news on the engine
and the car has come a long way
:) keep at it paul

[craig green]

Wow that does look good, I read Adams commenetd & tilted the laptop, looked again & was like 'yeah'.

Subtly different. Is it an 8v or 16v shell car?

[nova1992]

looks lovely mate!

[Paul]

Wow that does look good, I read Adams commenetd & tilted the laptop, looked again & was like 'yeah'.

Subtly different. Is it an 8v or 16v shell car?

Its a 8v shell, wa originally a 1400.

proof it runs (http://www.youtube.com/watch?v=n9qdEwSojZg)

[craig green]

Nice & light then!

[Paul]

yeh, and not rotten like all GTEs lol

[scott.parker]

So whats happened with the light to pipe issue then dude?

Scott

[Paul]

a lot of fibreglass, some mesh, some filler, some reflective tape and some black paint lol

[Paul]

Its road legal, has been for about a week now...

[Mazz]

Cool :)

Any finished pics?

[Paul]

yeh will get some when we next see each other...

[Southie]

I'd forgot about this thread :slap: for not subscribing lol

Looks really well now you've had it sprayed up, how's it drive though?

[Paul]

to be honest I havent even been in it yet, i ha a few things to do the day he got it out of the yard, and havent really seen him since, i do know the tracking and balancing needs doing though...

[dj_wudgey]

nice mate it go well with the saab lump in??

[hyprspec]

Any updates on this?

[Mazz]

Cool :)

Any finished pics?

*ahem*

[Connor]

Couple of pics i took at pv
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs535.ash1/31342_400266619925_637964925_4470951_6005106_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs575.snc3/31342_400266379925_637964925_4470950_8185679_n.jpg

[24sevenslacker]

saw this in total vaux mag, looks awesome

[Paul]

Its currently in bits, some silicon found its way into the oil pickup filter, and it run its bearings.

Was in TV a few months back.

Will update when theresmore progress.

[Dervy]

i red about this car in tv, great home made monster, good work feller :)