1268 replies to this topic

[Doctor Ed]

Couple of M8 rivnuts and the W2A intercooler core has a new home

[Doctor Ed]

Oooohhh... spontaneous eBay bargain buy... OEM Drexler LSD for the M32. Will park it for the time being, and will rebuild a second box (larger bearings, altered oil galleries etc) with the LSD once Ive got a feel for gear and diff ratios etc with the current wrecker-spec box.

Edited by Doctor Ed, 31 October 2017 - 12:16 PM.

[Doctor Ed]

From vockys build thread... but a diff is a diff... https://z22se.co.uk/...sd-1-jpg.67291/ https://z22se.co.uk/...sd-2-jpg.67292/

[vocky]

the guy I bought the LSD from said the bigger bearings and extra oilways on the improved M32 casing do nothing, they still fail.

 

He said run 3.5 litres of oil and it will never fail again. I am now running three litres of OEM LSD gearbox oil with the original size bearings and end casing (I have the improved casing and bigger bearings sat on the shelf)

[Doctor Ed]

interesting. makes sense seeing as the oil issue is the thing likely killing the bearings... which bigger bearings dont fix. Ill be a while before i put the LSD in, so have some time to think about which case/box i use as a rebuild base. as mentioned, i want to just get it running first, and see what the gear/diff ratios are like. speaking of which, whats the story with the crown/ring gear with these diff centers? which/what do you need to do to get them to play with the older boxes?

Edited by Doctor Ed, 31 October 2017 - 07:21 PM.

[Doctor Ed]

getting a crown gear in the right ratio is appearing more and more like unicorn sh*t..

so, photoshop overlay says it could be close...

eyeball-o-meter says:
- green probably lines up 1:1
- blue can be easily milled in a safe area
- red, yeah... probably be ok to drill a new hole here. not ideal, but would work
- between red and green... hmmm

(though if you work on the principle of clamping force providing the sheer to facilitate torque transfer, rather than it being taken through the fasteners, milling between red and green, whilst not idea, would still fasten down ok. just need some decent flanged bolts)

Edited by Doctor Ed, 01 November 2017 - 10:56 AM.

[Doctor Ed]

Exams/work killed the momentum lately

silicone intake bits arrived a few days ago tho, so quickly popped over to see how they fit up. All 5 ply bends. Still need to cut them to length, so itll get significantly shorter still (about 25cm in total coming out of it at various spots). Im pretty happy with it really. Only bend I got lazy with is the top 63mm (60deg) that couldve been a hardpipe. This just worked out neater.



Short of a crossover pipe over the cam covers, thats the entire intake circuit.

41mm ID compressor outlet
transition to 63mm OD crossover pipe
63-76mm OD transition into W2A core
76mm OD 180deg bend
90deg 76mm OD hardpipe
transition to 70mm OD throttle body

also got some spare time with the welder today. Fabed up some rubber isolator hangers/mounts and got the muffler mounted and sitting properly on its own for once. got the inlets/outlets kindve looking in the right direction, then looked at the pile of bends in the corner, and made some stuff fit. need to work some magic on the outlets, but shouldnt be too hard. main thing is the cat seems to be sitting about right, and should line up well with the turbine housing.

3.5 dump into the cat
3.0 cat into muffler
twin 60mm outlets

[Doctor Ed]

CAD'd up the firewall replacement and made a cardboard prototype from the numbers. Good that I did because I managed to fcuk it up. Not terribly so, so the pic below kindve looks ok, but it's wrong. Easy fix though, and won't need to make another prototype atleast.



Also got pedantic and threw 2x 60mm v-bands onto the muffler outlets. I'm not sure what I'm going to do with the exhaust - whether I'll incorporate the flow into the diffuser channel, or exit above the diffuser plane. Not sure basically, and want the ability to change it as i play with aero and the rear clam/diffuser assembly...

[Rosssco]

Are you going to do a V-band adaptor for the 4-bolt turbine outlet? Just curious..

 

Coming along nicely BTW!

[Doctor Ed]

Are you going to do a V-band adaptor for the 4-bolt turbine outlet? Just curious..   Coming along nicely BTW!

Thanks! Yep, 3.5" V band onto the turbine flange (maybe 1" of tube in between for clearance to the flange bolts)

[Doctor Ed]

Got home from work to find my doorstep had been gearboxed



Out of a Zafira B Diesel 1.7L

Should be a MZ4 box with 3.65 final diff ratio. Taller gearing will suit the power band of the A20NFT better, and the gearing is pretty evenly stepped with an overall slightly taller spread. Should push 900kg along quite rapidly...



Ratios from here:
http://www.opel-info...triebe/m32.html

[Nev]

I used to think tall gears were the way ahead, but now think the opposite. I hardly use 5th in anger as it's so long with 3.65 final drive.

 

You sound like a man who knows his plan, but I'd consider lower ratios if I were you...

[Doctor Ed]

Yup,I have a 3.9 final drive and a tighter ratio box here too. Dont forget it's a 6sp tho, and Germany has autobahns ... with a low ratio 6 I really think it'll be rowing through gears way too much. 5th will still be a usable power gear. 6 for autobahn cruise and that stupid long back straight of the Nurburgring

[ChrisS1]

Good progress as always. Keep up the good work and the updates

[Doctor Ed]

Thanks mate

ARP Pro flywheel bolts (8740 200000psi vs 175000psi for 12.9)
4AG 203-2802
M10x1.25 1.050" UHL

Figured it was the safe choice for a 5kg buzzsaw sitting around 50cm from my back, with only a bellhousing, a single thin sheet of aluminium and a fibreglass seat shell between us.

Edited by Doctor Ed, 23 November 2017 - 08:39 AM.

[Doctor Ed]

lol ... carnts fcuked!

Yeah mate, still drove, just made a bit of whiny noise

Already felt the bad joo-joo when I spied a case crack on one of the case recesses for a shaft bearing



Then this...

Edited by Doctor Ed, 23 November 2017 - 10:05 AM.

[Nev]

F*ck me, that is mental. Did the seller claim it was in "good working order"??

 

It looks as bad as as the "well maintained" VX220/gearbox that Glen Wood bought off Martin.

Edited by Nev, 23 November 2017 - 10:26 AM.

[Rosssco]

That's a reasonably impressive bit of gear wear there..

 

RTS for that one!

[Doctor Ed]

Nah, no RTS sadly... I bought it on the basis it needed looking at, but the bloke slightly unterstated how bad it was. Worst case scenario I wanted to salvage the pinion shafts and crownwheel our of it, but stripping it further just now (have come in for a calming coffee) shows pretty much every gear has chunks missing, making the box essentially a total write off. At the very least I now have a clutch installation alignment tool

[Doctor Ed]

so final (fatal) analysis...

essentially i have bought a 100 clutch alignment tool. that, plus i got to test my theory of the diff/crownwheel bolt PCD/alignment. everything else has been tossed in the bin (conveniently today was trash day so the missus at least doesnt have to put up with a gearbox carcass hanging around the house).

pinions were both fcuked:


crownwheel was fcuked


random collection of fuckedness:

Edited by Doctor Ed, 23 November 2017 - 12:24 PM.