Building a fast 16v Allegro (maybe)edk83 |
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| Member Posts: 62  | I bought an Allegro 1500 Super from Kieran on here, it was setup pretty much perfectly - Bike carbs, polished and ported head, aggressive cam, custom manifold, individualised mgf hydragas etc  Drove it around for a while, great fun. Had to change the steering rack after a bearing died, put a stereo in it and refitted Ford esc ignition to the existing trigger wheel that Kieran made. The electronic ignition gave it some more power, but made it harder to start to the point where I had to use jump leads and another car if it was cold! Nothing wrong with the battery, just the starter pulls a lot of current and its not quite big enough. I spotted someone selling a completely rebuilt 1750 engine, rebored to 1.8, new pistons from New Zealand! This bloke had gone mad, must have spent hours and hours cleaning everything, replacing everything else. He was asking for £500 but needed it gone due to moving house, I got it for £170! Here are some pics of his build, you get half an idea of the amount of effort that went into this! New bearings, new valves reground, new pistons, every gasket new. Even came with new spark plugs, but I used those! New heater matrix and other bits too.         This is how it sits at the moment, I have painted the block to stop it rusting as it was so spotless, also left the head on it to stop the surface getting crusty. I changed the water pump for an Allegro one rather than Maxi. Put a nice blank on the fuel pump port as I would be using electric not mechanical. I might swap the oil filter assembly over to use the disposable type rather than paper element.  All this is now plan B, I was going to use the new 1.8 bottom end with the current modded head and cam shaft. Plan A is make it 16v K series but it could go either way at the moment. I have been searching online quite a lot and can only find two other threads where people have thought of putting a K series in a Allegro, neither of them have attempted it though from what I can see. I don't want this to be a third failed try, but I think I have got a little further along. It just depends how much help I can get with the welding and fabrication. So far I have taken this nicely setup car and taken it to bits!     Some rust to sort out, I'll take the brake booster off and clean it, I think its only surface where brake fluid has taken the paint off.  Started cleaning up the engine bay...    I bought myself a rover 114 as a donor car, £230 quid with a full mot! I have done about 500 miles in it now and its nippy! 38K miles on the clock, rusty back arches and front hydragas is totally flat! It has just had the head gasket done and runs perfect, noticed a coolant leak due to split top water pipe yesterday so fixed that this afternoon.  I also bought myself an MGTF front subframe that has just come out of a Rover 100, it has metro hubs and arms, engine mounts already attached. Got myself some TF rear shocks for it too.  Did some measuring today, couldn't offer it up fully but it looks possible on just about every angle! The distance between the top of the suspension towers is the same +/- 5mm. The rear mounts would end up level with the bottom chassis which is open and easily accessible. The front mounts would end up either side of the tie bar mounts at the front of the car. I don't think much of the firewall would need to be cut, looks like the existing steering rack could even be used. The subframe would end up just in front of the firewall as on the metro.  All the front turrets will need to be cut away, all the sides of the inner wings, battery tray is currently where the left engine mount would end up. Front valance will probably need trimming and rad would be tight. But those are all the main problems I can see at the moment, pcd adapters could be made to keep the stag wheels and get the offset right, if I use a pg1 box or Rover 45 r65 I could keep the hydraulic clutch hopefully. Other than that the dimensions are so close its begging for it, the TF turrets are not as tall as the Allegro so it could end up quite neat and it's even asking for a custom strut brace where the top engine stays used to be! The endgame would be 1.8 vvc, I'd probably get an MGZR as another donor. I just need to find someone local to come and do the welding and fabrication. If I can I'll crack on the taking all the suspension and hubs etc off, if not I'll clean it all up and fit the 1.8 Maxi engine. Any advice would be helpful at the moment! Edited by edk83 13/1/2016 11:30 PM | ||
| Marv_666 |
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 '88 MG METRO 1300 Posts: 1117   Location: Dudley, Midlands | |||
| petrol_head |
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 drive it like its hired    | |||
| 111Sli |
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 Transport Guru MP Moderator Posts: 4947 Location: Bromley, Kent | |||
| 100Vi |
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| edk83 |
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| Member Posts: 62 | Thanks lol  The handling on mine isnt bad, its on mgf cans which make it fairly stiff. The brakes are the main issue, tiny pads, may as well try putting your feet out to slow down! Hoping a thicker metro anti roll bar and maybe a custom strut brace will help! | ||
| DotMatrix |
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 Expert Posts: 4458 Location: Jelling, Denmark | super cool allegro! makes me want to buy a 1750 allegro, tune it and race it  | ||
| edk83 |
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| Member Posts: 62 | |||
| edk83 |
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| Member Posts: 62 | On it with the grinder today, more came out than I was planning but the TF frame looks very close, no going back now!       Drilled me a new hole in an alternator bracket, just needs a trim.  Frame looks good from here but still needs to go back an inch and up an inch, more cutting needed.  Stripped the front end, looking sorry for itself! Frame definitely needs to go back and up!  | ||
| DotMatrix |
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Expert Posts: 4458 Location: Jelling, Denmark | |||
| edk83 |
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| Member Posts: 62 | |||
| DotMatrix |
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Expert Posts: 4458 Location: Jelling, Denmark | glad to hear you thought about it you could also make tubular support from the bulkhead to the front subframe mounts and then weld the whole front in one removable piece? | ||
| edk83 |
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| Member Posts: 62 | |||
| edk83 |
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| Member Posts: 62 | Decided my 13" steering wheel is too small, couldn't see the top half of the speedo before. Ordered a 14" one with a bit of dish, also a slim quick release collar - may or may not use that. Need to order a kk154x boss now, like the idea of it being crushable. As for the speedo - MGF clocks?  Should have kept the top cover  Or this is my preferred solution Got his Acewell this week, the mount can go the other way up.  going to take the entire dash out I think , the car's wiring is pretty good but I will have to change a lot of it. | ||
| edk83 |
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| Member Posts: 62 | Post man has been This stuff came direct from China in a week, tax free  Pump, filter and Alloy 30 Litre tank.  The brackets on the tank took a beating through the Airport sorting! They are fairly thick though and should bend back easy.  Hmm the sender float is only about half way down at it's lowest point, will have plenty of fuel left when the gauge says empty. It has about 2" of foam in the bottom, was expecting more. Is that enough? Was thinking I could try and add a block with a cut out for the sender. It has a lower part inside the tank so shouldn't need a swirl pot, will mount it with the outlets towards the rear of the car, maybe at a slight angle so there is always fuel at the outlet.  | ||
| glyn-ellis |
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| Elite Veteran Posts: 697 Location: leigh | |||
| glyn-ellis |
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| Elite Veteran Posts: 697 Location: leigh | |||
| edk83 |
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| Member Posts: 62 | |||
| edk83 |
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| Member Posts: 62 |  At least my floors are good, ordered some ally seats today | ||
| edk83 |
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| Member Posts: 62 | Had to cut into the steering rack mount section but that will get remade, rear of the subframe now fits!  Started cleaning up the subframe today, got rid of all the bits of brackets where the front arb used to be - thats something else I have to sort down the line.    | ||
| edk83 |
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| Member Posts: 62 | Frame fits! Just a small amount of welding to do now lol!    | ||
| Jin |
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| edk83 |
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| Member Posts: 62 | A bit more progress on the Allegro today, rear subframe mounts roughly made, but in the right place this time! Cut out the rear of the front panal for extra room, plated that off and whats left of the front of the chassis rails ready to accept brackets to bolt up the front of the subframe.    | ||
| edk83 |
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| Member Posts: 62 |  Got these back today, a little bit of drilling work! Just need to find someone with a big bearing press now! | ||
| edk83 |
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| Member Posts: 62 | Added some webbing to the front subframe mounts, this might foul the alternator on one side so may have to mod it later.   Gearbox mount back from bead blasting  | ||
| edk83 |
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| Member Posts: 62 | Knew it would fit    Mgf rad fits up front, manifold might be a little close but nothing a little front panel modding wont fix.  Alternator fits, even on the stock mount with about 5mm clearance.   Cluch master fits, might change to cable though.  Brake master doesnt fit thought!  These are ET45, might try ET35 as there is some room.  Also turning left this happens!   Hoping less offset will help with thinner tyres. If not might have to use 14" wheels, how do minis get away with it? Metro engine mount arm instead of mgf maybe? Looks better straight!    Edited by edk83 13/1/2016 11:32 PM | ||
| edk83 |
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| Member Posts: 62 | Wheels have been painted and polished  Also finished the boot tank install and made a rear strut bar.  | ||
| edk83 |
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| Member Posts: 62 | Well I have been pretty Ill since just before this weekend, went out and looked at the car for about 20min. Decided there is far too much work than I could ever do and got a bit down about it. So I went back to bed and did some retail therapy, now I'm both Ill and broke but have some bits on the way that are probably worth more than an Allegro each! Obp pedal box from a Nova, can be made to fit I think.  Type B Torsen diff arrived today, getting stored safely under my bed until needed.  And my wheels turned up from Austria! Just waiting for the centers and need to get a tyre on one but clearance looks good. Shame I'm now out of cash untill after xmas now, kids will see to that!  I did manage to order a polybush for the rear engine mount though, that is getting modded shorty to counter the fact the bracket was welded onto the frame 20mm out doh. | ||
| pickford |
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 Extreme Veteran Posts: 586 Location: brighouse just shy huddersfield | |||
| edk83 |
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| Member Posts: 62 | Have been making a Metro / Rover 100 GTI front anti roll bar fit recently, its really not too far off, will just want some more modding to fit. Have used the rear anti roll bar mounting plates from an MGF cut down and welded on.   Had to cut into my nice subframe mounts but not too much.   Also been drilling holes to mount the tank now the boot is welded up.    Test fitted a Mk1 Golf front splitter, subframe will need modding and some faffing but the look is pretty good I think.   Edited by edk83 9/12/2015 11:17 PM | ||
| edk83 |
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| Member Posts: 62 | I havn't done much on the car the last couple of weeks, weather and other things have been putting it off. I have sent my ally seats away to have the mounts welded on, also managed to pickup a brand new drivers side sidelight unit. Decided the orange wheels are a bit too mint to be using in winter and pushing it around on. I really want this car to be usable and not have to worry about paint and polishing but part of me really loves the new everything builds. Picked these up this weekend as spare / winter wheels, very close to the rh wheels and good tyres on them!  | ||
| 111Sli |
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Transport Guru MP Moderator Posts: 4947 Location: Bromley, Kent | I can't wait to see this. | ||
| edk83 |
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| Member Posts: 62 | Been raining all weekend  Braved it for a bit to fix the wives leaking focus. Had a quick try on with the gold wheels, these are et30 and the orange ones are et33.      Get away with that i think on the rear? Plently of lock now on the front before they get near the engine mount. Orange ones have 50 profile tyres rather than the 55 too. Also I feel an All'agro badge coming on!  | ||
| DotMatrix |
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Expert Posts: 4458 Location: Jelling, Denmark | wheels look nice | ||
| edk83 |
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| Member Posts: 62 | Not bad for a spare set, finally got my BL centers from Portugal for my orange wheels.   Allegro appreciation society are not impressed! | ||
| edk83 |
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| Member Posts: 62 | Well today I took the wife's focus for an MOT and went and pressed out the duff new wheel bearing for another one. Pain in the bum getting the inner race off the drive flange, good job the nice mot place let me loose on thier vice and grinders Also managed to pickup a brand new Mk1 Allegro Grille surround and center, these are the best looking I think, not easy to find though.  Worst thing that happened this week though 50mph winds and me being a dumbass! My car tent was slightly lifting at one corner due to a bit of foam being wedged under it. So I lifted it to try and get it, big mistake - wind got under the tent and it went about 15 foot high! I held onto the back end of it so the front of it came down and attacked the car. Lost a mirror and the wing and door are battered! The door was dented anyway and the wing is rotten at the front. Not sure now if I should get a fiberglass wing or repair this one!  | ||
| Marv_666 |
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'88 MG METRO 1300 Posts: 1117 Location: Dudley, Midlands | |||
| Metromartin |
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 MP Admin Posts: 17870 Location: Gloucester | |||
| edk83 |
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| Member Posts: 62 | Thanks mate The center caps came from Spain and the Wheels from Austria! Looking at getting another door then repairing the wing. A bit more done recently, nothing major. Have been wondering about fitting bigger discs than the mgf 240mm, tried some Honda 282mm discs, um shame the caliper has to go in there too!   Test fitted up the 240mm setup in 14" wheels, at least thats all good.   Started cutting up a Rover 200 gear linkage, the stabilser bar will just shorten but the selector rod will need a mod just behind the gearbox, not difficult though.  Modifield the lower rear mgf engine mount to compensate for the bracket being welded to the subframe 20mm out!  My ali seats now have mounts welded on Will have to build up the drivers subframe once I get the steering column mounted. Also picked up a slim rad fan that fits the mgf rad.  Removing horrid sound proofing (wish I hadn't started) Co2 fire extinguisher make a good job of freezing it though!  | ||
| edk83 |
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| Member Posts: 62 | This should make it Choo Choo! A bit of measuring up for roll cage today, working out how the heater and dash will fit.  | ||
| edk83 |
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| Member Posts: 62 | The sun has been out this weekend so got a few more hours in. Cut back and rewelded the lower subframe mounts so the Metro Gti arb now clears, planning on reinforcing them further later and also adjusting the bar slightly with some oxy heat.  Found a plastic alternator cover from an MG TF, nice  Started on new inner wings, i want to be able to lift the whole engine and box in and out with minimal fuss.  Gear linkage is almost there just needs a little mod to clear the arb then it can be blasted and welded properly.  Front strut brace looks like a easy job, will be bolt in and join up with the old upper engine mounts on the inner wings / old towers.  Nice bit of old crash damage, explains why the front end looks a little drunk even though the frame is perfectly square to the car.  Rad is half mounted, Allegro top mounts fit the MGF rad perfect | ||
| forcker |
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 Regular Posts: 241 Location: Germany | |||
| glyn-ellis |
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| Elite Veteran Posts: 697 Location: leigh | |||
| edk83 |
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| Member Posts: 62 | Thanks It has now been a year since I dropped the Allegro E Series out. It's come on a fair way, didn't touch it for a couple of months at the beginning of last year as I was stripping donor cars. I still only get weekends on it until it starts getting light in the evenings. 70s car with a modern injection engine is perfect I think, although the Allegro has the extra joke factor. I have seen the Austin 1300 vvc, his name is Ollie and I wish I had a cnc mill too! Some nice work on his part, love the Honda rear disc conversion milled from the original drum. Have asked him to keep the manifold plans just in case I decide to go turbo too! | ||
| edk83 |
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| Member Posts: 62 | Well I now have a working gear linkage, very direct too. Also the exhaust is all mocked up, just need to get it tacked together then mig welded as I made it from hacking up an mgf stainless exhaust. Also have to relocate the front hanger and weld that onto the subframe. Yesterday I had a bit of time so got a bit further making the inner wheel arches look tidy after attacking the sound proofing with a fire extinguisher.  Have now got a complete set of non dented, rust free doors, the rear two are in the shed.  I mounted the drivers seat on some wood to try and check the height and door bar fitment. Actually sat in the car for the first time in over a year yesterday, felt good even though the steering column is too high and seat was a bit loose! Also mocked up the roll cage in card tube, its still going to be a pain to measure properly!    | ||
| edk83 |
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| Member Posts: 62 | Collecting the cds tube tomorrow hopefully. The sun came out after lunch today so got on with the things needing to be sorted while the spare engine is in. So now the obp pedal box has a throttle cable that does something, was just a solid bar that moved which is odd. Now drilled and threaded with a motorcross cable. Cant actually see the bit I worked on in the pic, but its another job done!  Exhaust is now all sorted, tacked the chopped up stainless together today and it's been unbolted to be tig welded. Rad mounts are also done as is the gear linkage. All just tacked up with the exhaust in the pics but I've taken it off and its been fully welded now. I'll get around to fitting the new rubbers and painting it up sometime. Spare engine pulled out today now thats all done. Have to move the car in the next couple of weeks so will be making an A frame to clamp onto the subframe then tow it like a trailor.   Today I have fitted my torsen b diff and checked out the inside of the gearbox. Shocked it went back together all ok Must remember to put oil in it!  Here is a pic of the bottom rad mounts fashioned from mgf top mounts.  Also been cds tube shopping today, quick offer up and it looks good although a lot of work.  | ||
| glyn-ellis |
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| Elite Veteran Posts: 697 Location: leigh | |||
| R100TUR GTa |
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| Elite Veteran Posts: 757 Location: nottingham | Didn't realise you were on here! I bought the 200Vi interior off you a while back, glad to see you project coming along nicely seem to have done quite abit since last summer when I saw it. | ||
| edk83 |
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| Member Posts: 62 | Tube is msa spec cds. I got it from Tom at tubebender. Very good as it all fits to my drawings and he beat all the other quotes I had. Yep I'm on here, handy as many parts are metro. It's coming on slowly, hoping to have it running end of summer and on the road sometime after that | ||
| edk83 |
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| Member Posts: 62 | Got the modded mgf stainless exhaust back from the tig welders Most people do stainless cat back, guess I'm just backwards! It connects to a modded 2" mini system with a cherry bomb then a sportex backbox. It's in good condition but it might get remade in stainless later.  The sun has been outday so have been making new inner wings that come down to meet the gearbox and alternator covers from the mgf. Slight bobo we welded the inner wing to the tower on the subframe lol. Will slice and put a joining plate in later.  I have decided that for the rear suspension I'm going to try and copy Jonny's coil and top hat design like this. The Cv type gaitors on my hydragas cans are a bit knackered so rather than depressurise to change just the gaitors might as well do the conversion.  The mgtf shocks that I have bought won't do for having a tube to take the knuckle tig'd to the top so bought these from a robin hood kit car, should be able to chop the top eye off and build from there. They are height adjustable, might get some gaz dampers later but don't like to cut up expensive ones!  Next job is build an A frame to bolt to the subframe and tow the car to new house! | ||
| DotMatrix |
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Expert Posts: 4458 Location: Jelling, Denmark | |||
| edk83 |
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| Member Posts: 62 | |||
