Author Topic: CONMAN´s Calibra Turbo project (Read 56254 times)

conman · « **on:** August 08, 2014, 14:34:02 PM »

Hi there.
I presented my car in the new members section but figured I would do a project thread too.

2001 It all started when I bought the car, an Opel Calibra Turbo -93
Then it was equipped with 17 "Antera rims, DTM skirt package, Enem Chip and good sound with a 12" woofer in the trunk.

2003 Starting the evolution, 19 "Ace wheels, vectra handle without lock cylinder, air hole in the hood for hotair and some extra holes in the front bumper and SAAB 9-5 Aero 308mm brakes.
For performance I welded a custom manifold for a Mitsubishi TD04-18T turbo, mounted a large intercooler, Volvo 465cc injectors and installed a unichip.

2004 next step was to replace the TD-04 18T turbo against a KKK 24 Volvo S60R. The exhaust on the side after the driver's door, fiberglass hood and ACE Tyson Black 19 "

sealeysonic · « **Reply #1 on:** August 08, 2014, 14:45:49 PM »

very nice !!

conman · « **Reply #2 on:** August 09, 2014, 07:49:43 AM »

Thanks.

After a blown engine and a broken transfer box, I decided to do it properly.
Said and done, the entire body was cleared of everything. A cage was welded in and the body was modified for rear wheel drive.

First, tear out all of the car.

Then weld the cage.

Front to hold the wheel bearings

The rear axle, a diff and drive shafts from omega 3000.

Carrier comes from omega 2,4 and are machined 5mm to fit with calibra hub and omega drive shafts.

zodiac245 · « **Reply #3 on:** August 09, 2014, 08:09:09 AM »

Did you log the man hours? A friend is restoring a pre-war convertible that had been in a garden for 50 years. He is over 500 hours in and has barely started.

For anybody involved in software I would recommend reading "The Mythical Man Month" by Fred Brooke's. It is quite old now but still relevant.

conman · « **Reply #4 on:** August 10, 2014, 08:05:35 AM »

No I have not logged the man hours, but there are not as many as you might think.
Locate parts and get Garage time is the hard part

2010 late fall, I began tear the body. 2011 late spring I welded the cage.
The rest of 2011, I was looking for parts, and I also built the engine.

michail · « **Reply #5 on:** August 11, 2014, 08:48:36 AM »

Great upgrades!
is that a z20let oil pump?which brand of pistons,conrods are you using?

Keep up the good work and don't forget to update!!

conman · « **Reply #6 on:** August 11, 2014, 19:39:19 PM »

C20let block rebored to 86.5mm and extra cooling channels,
ZLET oil pump with modified oil pickup pipe,
Willams H section steel con rods with ARP bolts,
Wössner 86.5mm pistons,
ARP head- main cap- flywheel bolt/studs,
Balanced and polished crank,
Male lead/copper bearing,
Cometic head gasket,
Coscast head with extra cooling channels,
New timing belt, idler, tensioner, water pump and 8v sump gasket
low temp thermostat,
custom inlet manifold,
70mm billet throttle body,
50mm bov,
tial wastegate,
custom exhaust manifold,
Garret gt3071r,

And some pic´s of parts
custom watercooler, 87cm wide, 36cm high and 5cm thick

Intercooler cell 50cm wide, 35cm high and 7cm thick and two bov´s ended up using just one,

custom inlet manifold with 70mm billet throttle body and 1200cc injectors

Tilton three-disc clutch and balanced c20xe flywheel

Nira i3+ engine management systems

rear bushes

H&R coilovers

standing pedal assembly

Digi Dash

70mm billet throttle body, fuel pressure regulator and 1200cc injectors

welded BMW ZF transmission

Garret gt3071r with td05 exhaust house

custom part

electric power steering

mircea.armeanu · « **Reply #7 on:** August 14, 2014, 13:34:08 PM »

Hello!
Nice thread to read & awesome mods!
I'm particularly interested in the electric power steering. Can you give us more info? From what vehicle is the sistem? What mods are implied, etc!
Thanks & Good luck with the project!

conman · « **Reply #8 on:** August 15, 2014, 18:48:13 PM »

No modifications there are only two oil lines to the steering gear then 12+ and ground. The unit is a new spare part for a Volvo 440.

conman · « **Reply #9 on:** August 23, 2014, 12:01:23 PM »

The next step was to use an empty block to make motor mounts and fit the engine and gearbox.

When the brackets were finished I put in the correct engine.

Then it was just to fit in the remaining pieces around the engine, radiator, intercooler, intake, etc.

Then it was time to start

http://youtu.be/COX6QZp9dS0

angus346 · « **Reply #10 on:** August 24, 2014, 13:03:23 PM »

That is a brilliant project! Love the work you are doing. Can't wait to see more!!

conman · « **Reply #11 on:** August 30, 2014, 13:11:14 PM »

Thanks.

Here are two movies from stage one with three-disc clutch.

First start: http://youtu.be/COX6QZp9dS0

And a test drive @ work: http://youtu.be/3runXi0ArMQ

After some problme with titon clutch I rebuilt and used a single zinter with 618 pressure plate.
A movie from testdrive with that cluch: http://youtu.be/uXw7vmVW8pc

New 18" rims and lights redy.

Next step, paint....

conman · « **Reply #12 on:** September 07, 2014, 17:10:11 PM »

The next step was to get some color on the car. I chose to paint it with black Plasti Dip.

So here is how it looked before I started

Time fore paint @ work.

Completed, along with my Mokka

The next step was to switch from the 9-5 306mm brakes AP Racing 330mm

Bad Kid · « **Reply #13 on:** September 07, 2014, 23:08:39 PM »

Nice project! Tell me why you used the Omega rear diff, and not Calibra Turbo?

conman · « **Reply #14 on:** September 08, 2014, 04:04:11 AM »

Diff from calibra is the same as that from early omega, the small diff. Omega 3000 has the large diff with bigger shafts making it passed much more power.

Bad Kid · « **Reply #15 on:** September 09, 2014, 02:22:42 AM »

Okay great thanks. Is Omega 3000 a limited slip?

conman · « **Reply #16 on:** September 09, 2014, 05:26:45 AM »

Yes most of them have limited slip, but not all. To get everything to fit I had to take the outer lugs from omega 2.4 and shorten them 5mm. then I took the drive shafts from omega 3000 and all fits.

Bad Kid · « **Reply #17 on:** September 09, 2014, 10:10:37 AM »

Excellent stuff and very helpful thankyou

One last question - what is the steering rack and steering column from?

conman · « **Reply #18 on:** September 14, 2014, 09:02:03 AM »

Original steering rack and steering column. But the steering column is extended with a steering quickener, with 2.0:1 ratio.

Here are two pictures that show the difference between the small and the big diff.

The next upgrade of the car was a different front spoiler and mount the dashboard.

Then follows a summer (2013) of tuning and a lot of joyride and filming.

Of course some clips:
http://youtu.be/KlS-EGeOpRs
http://youtu.be/N3XEdylxWwA

Next i mounted a airvent on the roof.

A friend and I took a trip to mantorp and watched some cars, it was nice with the fresh air intake.

It last thing to happen in 2013 was that Bilsport (the biggest car magazine in Sweden) had a meeting in my town.

http://youtu.be/MQdoDm9LJ5E

The diff did not like the torque, so in the fall of 2013 I welded the diff. More in next update....

conman · « **Reply #19 on:** September 23, 2014, 09:25:10 AM »

An update of the project.
2014 New adjustable wishbones

The braking of the machine at overtake.se I had problems with the wastegate it would not give me more than 1,7bars boost pressure that resulted in the 450HP at the hubs.

a little video from overtake.se
http://youtu.be/88eKysnQxUM

I swapped the wastegate to a new precision wastegate and loading 2,1bar which should give at least 500HP at the hubs.

a little video from when I test 2,1bars boost
http://youtu.be/Bh-pY6R377g

I got home a new map sensor which gives me the ability to have 2,6bars boost.

I also brought home a BMW E39 rear suspension to be installed.

The rear end I have mounted now will be installed at the RWD project number 2, a 8v calibra to get a SAAB 2.3 Turbo and R25 / R28 gearbox.

RedCalibra33 · « **Reply #20 on:** September 24, 2014, 08:41:01 AM »

That looks awesome but crazy!!! Where do u find the time and money???

conman · « **Reply #21 on:** September 24, 2014, 12:14:14 PM »

michail · « **Reply #22 on:** January 04, 2015, 06:37:59 AM »

You're the man m8!!
there are no words to describe that state of the art you've done!!

conman · « **Reply #23 on:** January 04, 2015, 21:04:33 PM »

thank you.

I have ordered a BMW E36 steering rack and front hubs from 9-5, will build a new front suspension.

And tomorrow I start cutting out the floor to fit in the e39 rear suspension.

Jackos-se9 · « **Reply #24 on:** January 04, 2015, 23:27:54 PM »

Like all the work you have done, what a great project.

djrobski99 · « **Reply #25 on:** January 05, 2015, 18:05:16 PM »

Top work there. Car looks great.

Davebatenburg · « **Reply #26 on:** January 06, 2015, 23:00:53 PM »

Amazing calibra! Can you make a good pic of your aerocatch pins? I install mine on saturday but how your's fit it looks good

michail · « **Reply #27 on:** March 23, 2015, 22:51:21 PM »

Any updates???

conman · « **Reply #28 on:** April 25, 2015, 17:33:29 PM »

This will soon end up in my garage, will be some kind of daily driver. I´ll work more with the black one, make it more like a drift car.

The blue one is Qrew´s old strip car, have made 9,48 @ 402m

conman · « **Reply #29 on:** May 02, 2015, 17:40:29 PM »

Now both are at home in the garage.
The engine and gearbox from the black to be picked over in the blue, then it will be completely new engine concept in the black.
Leaning @ V8 twin-turbo

conman · « **Reply #30 on:** June 21, 2015, 18:47:54 PM »

New parts to the second calibra:
Gear shifter

Volvo v50 servo

Time for the engine and gearbox transfers

Almost ready to start

michail · « **Reply #31 on:** June 21, 2015, 19:03:30 PM »

Great parts & projects!please post some videos!!!

conman · « **Reply #32 on:** June 22, 2015, 18:38:28 PM »

No real videos yet, will come...

More pic´s, all my 3 calibra´s are now black.

my garage right now, my two rwd calibra:

conman · « **Reply #33 on:** July 30, 2015, 05:19:18 AM »

Children's cousins were visiting, so I offered a ride

https://youtu.be/s8DuyILzAgc

https://youtu.be/1qvH_ygPdZw

sealeysonic · « **Reply #34 on:** July 30, 2015, 10:05:54 AM »

Very nice....i love the matt black paint...they look evil!

conman · « **Reply #35 on:** August 17, 2015, 21:07:14 PM »

I have built another calibra this summer, with Saab 2.3 turbo engine, Opel R25 / 28 gearbox and Opel Omega 3000 rear axle.
It is not for me, but for a team running on track 6h races.

Now that I'm done with it so it's time to start with the V8 project

Parts...

Recipe:
BMW m60b40 with h-rods, stronger valve springs, new bearings and seals.
Turbo that can pump air for 1000hk.
BMW E39 rear suspension with E34 diff.
Adapter for engine M50 box and a GS653dz 56kg BMW gearbox.
Maxxecu with vag coils and 1260cc injectors.
Will do new bulkhead.
New floor from the bulkhead and rear.
Probably BMW E36 front suspension.

sealeysonic · « **Reply #36 on:** August 20, 2015, 08:15:16 AM »

Amazing work.....how do you know all this ?

michail · « **Reply #37 on:** August 20, 2015, 08:19:29 AM »

This guy will drive me mad!!!

conman · « **Reply #38 on:** August 27, 2015, 19:18:19 PM »

Thanks guys.

I have taught myself, trial and error.

A little more parts

Flexplate,waiting for the clutch kit. Gearbox I collect tomorrow.

BMW E36 front suspension parts

michail · « **Reply #39 on:** September 01, 2015, 07:14:22 AM »

I can't wait to see this monster in action!!!

conman · « **Reply #40 on:** September 06, 2015, 18:19:06 PM »

Steering gear found its place. This is just a test assembly to see what fits and what must be cut away.

Joest DTM · « **Reply #41 on:** April 21, 2016, 13:49:37 PM »

Conman, i admire your work man..

Tasty and yet as simple as it gets.

I have an original 4x4 turbo (9/93') which i am keeping as is.
And a rolling shell of a 1992 which will turn to rwd soon.

conman · « **Reply #42 on:** July 31, 2016, 22:55:56 PM »

My three calibra's in the same garage.

Two films when I was out and tested the tires.
It's R-tires 265 rear
https://youtu.be/EpEYdwDN_kM

https://youtu.be/03vbwD64tiU

conman · « **Reply #43 on:** September 02, 2017, 06:30:01 AM »

https://youtu.be/RIpwibOF504

calibul · « **Reply #44 on:** September 03, 2017, 22:42:34 PM »

Cool! I can smell it

sealeysonic · « **Reply #45 on:** September 04, 2017, 11:16:15 AM »

god knows how much money you have spent....epic build

conman · « **Reply #46 on:** July 23, 2019, 19:07:22 PM »

Someone who wants to buy my first rwd body? rear subframe for bmw e34 210 diff and axles. Shaft rated 1000hp+. Full cage in the body, glassfibre bonnet and trunk.
1000$

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Author Topic: CONMAN´s Calibra Turbo project (Read 56254 times)

angus346