Engine swap plans / checklist help!

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Engine swap plans / checklist help!

Postby jifop » 19 Feb 2005, 19:13

hi all, i'm putting a 1600 xflow in my chevette and need someone to look over my plans and to advise me.

this is my daily car (90 miles a day) so i need minimal time off the road

1. sort the braking, was looking to use vented chevette disks with volvo calipers, i assume they will go straight on without modification to the master cylinder? also what make/model of volvo am i looking for?

2.i dont want to lower it madly as i like a little off road driving occasionally so probably going to only cut an inch or two out of the springs and get some gas shocks

4. a good friend is building the xflow for me (he used to build xflows for a motorsport company), i will modify current ashley exhaust to fit, this will then go in with a 5 speed escort gearbox i guess a new gearstick hole will need to be made and the old centre console removed

5. prop, for now i will make a prop on a lathe using the old chevette one and an old ford one.

6. i will keep the chevette rear axle for a while and then replace it with a manta b axle? how hard is the fitting of that? what mods need to be done? once manta axle installed i will get a new prop made, put the twin carbs on and tune it up. i assume i can use the manta drums fine? is the stud pattern the same?

7. VROOOM should be fun

thanks in advance for help/advice.
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Re: Engine swap plans / checklist help!

Postby hsr2.6 » 20 Feb 2005, 00:37

jifop wrote:hi all, i'm putting a 1600 xflow in my chevette and need someone to look over my plans and to advise me.

this is my daily car (90 miles a day) so i need minimal time off the road

1. sort the braking, was looking to use vented chevette disks with volvo calipers, i assume they will go straight on without modification to the master cylinder? also what make/model of volvo am i looking for?


you'll have to upgrade the mater cylinder because it wont cope with the 4 pots.make sure you space out the caliper from the hub by about 2or3 mm,you'll also have to grind the caliper to fit under 13" wheels

jifop wrote:2.i dont want to lower it madly as i like a little off road driving occasionally so probably going to only cut an inch or two out of the springs and get some gas shocks


sounds about right

jifop wrote:4. a good friend is building the xflow for me (he used to build xflows for a motorsport company), i will modify current ashley exhaust to fit, this will then go in with a 5 speed escort gearbox i guess a new gearstick hole will need to be made and the old centre console removed


yes you'll have to cut a hole further back

jifop wrote:5. prop, for now i will make a prop on a lathe using the old chevette one and an old ford one.

6. i will keep the chevette rear axle for a while and then replace it with a manta b axle? how hard is the fitting of that? what mods need to be done? once manta axle installed i will get a new prop made, put the twin carbs on and tune it up. i assume i can use the manta drums fine? is the stud pattern the same?


the std axle is safe to 100bhp,if you use the manta b you're gonna have to arch the car because it's about 2" wider, you need a manta a.stud pattern is the same

jifop wrote:7. VROOOM should be fun

thanks in advance for help/advice.


Doive edit: aren't we good to you!
rally drivers do it sideways.............well the quick ones do....................
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Postby hsr2.6 » 20 Feb 2005, 00:38

that came out wrong read the reply's to each question :wink:
rally drivers do it sideways.............well the quick ones do....................
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Postby Guest » 20 Feb 2005, 16:27

thanks, any recomendations of what master cylinder to use?
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Postby hsr2.6 » 20 Feb 2005, 19:14

i'm sorry i would'nt have a clue,you'll have to ask one the lads on here,you'll have to find one that will produce enough pressure to fill the 8 brake pistons...
rally drivers do it sideways.............well the quick ones do....................
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Postby Shoveitpusher » 21 Feb 2005, 09:15

the standard master cylinder will cope, mine did for a couple of years (manta drums on rear) before i got a bias box. pedal is just a bit longer. disks are usually vented from a carlton.

i can't remember if i spaced the calipers either, offer them up and see.

generally search through the site for brake advice, there are loads of options mentioned.

i wouldn't lower it at all if your going off road, bounced mine on its nose with lowered rear springs. 2" will be useless off road and don't forget the springs are not 1:1 ratio so don't cut an inch off the spring and expect the car to be an inch lower (sorry no idea what the ratio is)

a mild xflow shouldn't worry the axle too much but start putting more power out and it may fail. fitting of a manta axle is also to be found on the site.

biggest question is why a xflow? if it's coming very cheap then ok otherwise the sohc vauxhall engines are a much better bet, easier power, more refined for longer journeys.
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Postby shuvit-tim » 21 Feb 2005, 09:25

your standard axle is good for up to 100BHP, above that, it'll snap under heavy driving.

brakes: plenty of info around th eforum, but if you want to go for the volvo upgrade, you need 240 calipers, and carlton 2.2 discs (preferably vented).

the rest all seems like it should work though. Budget for a few little extra things that you havent considered though, they always crop up!
when all else fails, rivets, cable ties and bodge tape will see you through

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Postby craigm » 27 Feb 2005, 17:07

you can fit a manta servo and master cylinder which will displace more fluid than the stock chevette one . you need to unbolt the pressed mounting bracket from the back of the chevette servo and bolt it to the manta one , then extend the clevis by 3/4 of an inch (19mm). i did this by welding on a couple of nuts . only other mod is you might need to make a small amount of clearance with a hammer and piece of wood to the inner wing because the larger servo just makes contact . i didn't have any clearance problems with a late chevette but i did with an early one . i had a 1600 crossflow chevette and it was an excellent performing car for the amount of time and money that it cost but that was in the days of leaded fuel.
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