here we go again

[Engineer1949]

as if theres not enough going on now embarked on another upgrade and alteration of the chim out with the lt77 in with a tremec tko600 steel flywheel 10.5in mcloed clutch centre push release bearing then take the suspension spring rates back to standard still on the ohlins fit road tyres so making a fast gt cruiser be great to get her out on the road again in company with the wedge,as usual lots of pics of the doings.


john

[Engineer1949]

peter the ohlins have served us well very sensitive to the adjustment and seemingly well made penskes are also a good bet but they all come at a cost,once its back on the road please do have a go wont be quite so track focused but might still surprise.


john

[Engineer1949]

daz cant realy give you a price as not done it yet problem with using this box on the rover is no bellhousings available so i am having to heavily modify the existing lt77 one will be starting that next week so watch this space but as to the job box is out flywheel and clutch off and have had the tko600 mocked up in place looks tight but doable i have ordered the centre shift kit and the new clutch and have machined the flywheel just the fixings to do today on the rotary table.


john

DSCN2397 by Brundall Motorsport, on Flickr

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[Engineer1949]

fair bit got done today finished the machining on the flywheel all looks good picking up some cap heads to fix it on with tomorrow also got the pilot bush out and machined it out for the tko input shaft and started measuring up ready to start the bellhousing mods.

john

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[Engineer1949]

lots of maching not quite there yet but well on the way made a register plate to centralise the new gearbox when mating the two parts of the new bellhousing prior to welding then cut the required amount off the bellhousing to bring the spigot forward to fit into the crank spigot bush then started maching the register hole for the tko600, next draw the outline and cut the plate on a band saw prior to welding together.

john

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[Engineer1949]

thanks mathew glad you like them,had another day of machining finished the register hole in the 20mm ally plate much twiddling of the rotary table handle then marked out the basic shape to cut it into to allow both bellhousing and gearbox to fit snugly, couldnt find anyone to lend me there band saw so cut it with a jigsaw took over 3 hours was i glad when that was finished then marked out the fixing holes and drilled and tapped them on the mill so all nice and square.

john

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[Engineer1949]

your not far wrong richard but being an old iron fighter has its benefits.


john

[Engineer1949]

started putting things together flywheel on and clutch but not before turning up a clutch centring tool for the mcloed clutch all looks good, then stripped off the shocks and started cleaning them and then removed the heavy weight springs from the nitrons and removed the standard springs from the original bilstiens and built the rears up with the standard springs and refitted them, the teflon liner also arrived for the mig so much welding today then skim the faces to make sure they are square.


john

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[Engineer1949]

cheers for that but the tool has a second function once the bell housing is finished i can check the alignment with the tool and bell housing fitted on the car prior to fitting the box.

john

[Engineer1949]

i am the wrong side of the pensionable age and have had five apprentices all seem to have done o.k. but being a one man band suits me now but if anyone needs help or advise just give me a call.

john

[Engineer1949]

well all went well today got the bellhousing all lined up and tacked it to the mounting plate then fully welded the two together, after it was properly cooled i mounted it on the mill table to skim the plate where it meets the gearbox to assure a level mating surface it had warped about 15thou after welding so with that done i mounted it all on the gearbox and refitted the register plate to be sure everything was spot on, then fitted the bellhousing to the engine to get the measurements for the fitting of the centre push release bearing.


john

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[Engineer1949]

back in the workshop had a great break but glad to be back, got the remaining shocks sorted with the standard springs and refitted then stripped the tko 600 and fitted the centre stick conversion all went well apart from having to turn up a drift for the roll pins securing the selectors.

john

DSCN2471 by Brundall Motorsport, on Flickr

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[Engineer1949]

yes its a kempi mig running 1 mm wire 5% silicone with a 1.2 mm tip with pure argon shield amps around 225

john

[Engineer1949]

you say you nearly gave it away does this mean it is still available

john

[Engineer1949]

yes ole you can buy ally specific tips but at a premium so most use the next size up as you say stops the wire sticking.


john

[Engineer1949]

last major obsticle overcome sorting out the throw on the centre push release bearing much measuring and then turned up a spacer with the same mating taper as the box and bearing so go for box fitting next to check all good then sort the pipework from master to centre push and centre push to bleed nipple

john

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[Engineer1949]

bit more done stripped the wiring from the map sensor and the no.8 injector as the water injection had packed up seems the flux i used when soldering the joints has attacked the wires and turned them to dust hence the lack of injection so got a new map sensor plug and will invest in some new fluxed core solder before rewiring fitted the bellhousing and started on the plumbing for the clutch slave doing it all in 600 series aeroquip so had to silver solder up an adaptor from 1/4 brake pipe to jic-3 got the bellhousing sorted with two bulkhead fittings and plumbed up inside the bellhousing so coming along nicely.

john

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[Engineer1949]

bit of an update after the autosport show i have removed the master cylinder that goes with the triple plate clutch and installed a 3/4in one for the centre push bearing thoes two bolts are a nightmare on your own must sort a better method then finished the plumbing to and from the slave one pipe ends in a bleed nipple right next to the remote resevoir then i have removed the seats and harnesses and sorted the drivers side lap and diagonal seat belt works better than i thought considering the seat type so gearbox install monday all being well

john

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[Engineer1949]

another good couple of days, fitted the passenger seat belt and replaced the seat then the biggy to install the gearbox had to go in complete so meant angling it up and to one side to get the bellhousing inbetween the chassis rails but all went well and it was soon bolted up, next fabricate a new gearbox mount which wasent to bad uses the existing holes in the chassis but a little different as the mounting are perpendicular not angled ,then connected up the master cylinder and fitted the bleed nipple and bled out the clutch all seems to work well and smooth so onto the interior made a closure for the cutout where the new gearstick goes made a new gearstick and fitted that then refitted the rubber gaiter modified the cover to the door opener and then refiited the centre upholstery and finally screwed the gear knob and door opener on and now the gear knob decals are actually correct,then made a blank for the lower bellhousing cover welded that in place and refitted the cover,then rebuilt the left hand side of the engine that was dissmantled to get access to the clutch pipes etc. finally measured up for the new propshaft boxed up the relevant parts and sent them off so all in all not a bad couple of days.and also a purely graturious pic of the engine bay i do love that thing.


john

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[Engineer1949]

another update car is now up and running gearbox is very crisp clutch not to bad weight wise and passed mot with no advisories so all good then decided to sort the paint several years of track days etc. have certainly taken a toll lots of stone chips so attending to that and a couple of stress cracks also sent the steering wheel off and had it recovered in alcantara which has given it a amazing feel new 17in wheels sourced but 5 weeks delivery time being shod with michelin pilot sports 4 rubber


john

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