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May 12, 2013 18:56:22 GMT
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That is brilliant, some real 'outside the box' thinking there!
A how-to on modding the box to fit other engines would be much appreciated, as it could be the answer to people's prayers having a modern strong 5-speed that'll fit most cars without much cutting.
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1953 Minor (Long term project)
PT Cruiser
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May 12, 2013 18:56:38 GMT
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Excellent work !!!
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owen
Part of things
Posts: 287
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May 12, 2013 19:29:07 GMT
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This engine was a rare one, when i brought it it smoked and ended up being a piston broken between 2 rings, peugeots said they only made these pistons for 6 months and theres no stock, so I had to buy a different one and machine it to suit. the box is easy to mod for pug tu and tud engines you oval out the top 2 holes and then the botton 2 you screw the studs in backwards pointing towards prop end of box then weld a new stud to the side of it. sounds a bit bodgy but it works well, my old tud sj did 30000 miles like it before i sold it and I gave it a hammering, youtube cambsoffroading the bright orange truck was mine. I will put a picture of a modded box up. And for the starter you use pug one with top hole bolted in yo the box then turn starter until your happy with the noise it makes when cranking and drill a new hole for it. Clutch wise the diesel has a step in the flywheel so you either need a hybrid clutch or machine about 10mm off the sj plate to fit inside the flywheel, or put a petrol tu flywheel on it as they are flat and bolt straight on. I am turboing a tud at moment for a vitara so have put a flat flywheel on it so I can now run either the vitara 200mm clutch or the sj 180mm which both run the same spline. Also by drilling one hole out a bit for one dowel on the sj/vit pressure plate it bolts straight up so on the petrol flywheel you can run all sj clutch parts
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owen
Part of things
Posts: 287
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May 12, 2013 19:36:17 GMT
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You drill a new hole in the starter not the box
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owen
Part of things
Posts: 287
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May 12, 2013 19:40:37 GMT
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Heres the bust piston  |
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owen
Part of things
Posts: 287
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May 12, 2013 19:42:39 GMT
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Moded box you can see the ovaled holes and the studs are on the outside of the bellhousing  |
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owen
Part of things
Posts: 287
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May 12, 2013 19:43:55 GMT
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Heres one mounted to a 1.5d tud  |
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owen
Part of things
Posts: 287
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May 12, 2013 19:48:18 GMT
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Engine mounts are easy, on the nearside theres 4 bolt holes where the aircon bracket should mount and on the offside theres 4 holes ready tapped, I used sj leaf spring bushes as mounts as they push straight into scafold tube and are readily avalible in standard rubber or polly bush (I had some kicking about and I don't spend money unless I have to I'm a bit of a budget builder boy)  |
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owen
Part of things
Posts: 287
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May 12, 2013 19:50:58 GMT
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Gearbox mount is nice and easy, bolts to the box with 1 bolt and mounts to a crossmember with 2 m8 bolts  |
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owen
Part of things
Posts: 287
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May 12, 2013 19:53:35 GMT
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And for you diesel lovers heres the flat petrol flywheel fitted to the tud, this flywheel was off a 307 1.4 16v but my bro has one off an 1100 which is the same  |
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owen
Part of things
Posts: 287
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May 12, 2013 19:57:49 GMT
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Ive gotta mod another box for my dad soon so will get some better pics when I do it, and if your interested in other engines go on difflock.com forum on suzuki and search theres loads on there, people have even cut fwd bellhousings down and welded on to tje box to take the astra 1.7td isuzu engine and even the 1.9 and 2.0 vw diesels so if your handy anythings possible
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owen
Part of things
Posts: 287
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May 13, 2013 23:00:08 GMT
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Well I collected the new diff and shafts tonight so tomorrow night I will start putting ten back together
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ChasR
RR Helper
motivation
Posts: 10,309
Club RR Member Number: 170
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May 14, 2013 10:29:40 GMT
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Those TU5 engines from the GTi are superb units. They really do pull well for what they are. There are many who have disputed that they actually are capable of making book figures but the performance of them suggests otherwise  . Whilst I am a fan of AXs and 106s this conversion is great! No doubt that the car surprises a number of moderns . |
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sowen
Club Retro Rides Member
Posts: 2,245
Club RR Member Number: 24
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 When opening the dictionary the definition of sleeper should be this ^ That is a truly inspired conversion, must be so much fun going out baiting moderns  |
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MrSpeedy
East Midlands
www.vintagediesels.co.uk
Posts: 4,791 
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May 15, 2013 16:46:01 GMT
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Loving your work (but not at all envious of all round drum brakes ) |
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owen
Part of things
Posts: 287
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May 15, 2013 22:07:20 GMT
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Thanks for all the comments, got diff and shafts in tonight, made new prop up ready to weld up tomorrow, then gotta repair brake pipe and handbrake. Found out tonight that old owner put thinners in instead of brake fluid, took cylinders off to change shafts and it stunk of cellulose thinners, its not even oily like brake fluid
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May 15, 2013 23:50:54 GMT
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my new fav RR car
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Frankenhealey
Club Retro Rides Member
And I looked, and behold, a pale horse! And its rider's name was Death
Posts: 3,885
Club RR Member Number: 15
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May 16, 2013 21:26:23 GMT
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Exxxxxxxcellent  |
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Tales of the Volcano Lair hereFrankenBug - Vulcan Power hereThe Frankenhealey here |
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owen
Part of things
Posts: 287
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May 18, 2013 19:01:28 GMT
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Shes alive again, was quite an experiance to road test it in the rain last night, bit sideways if i looked at the throttle pedal
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owen
Part of things
Posts: 287
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Jun 14, 2013 19:19:47 GMT
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Well after a couple of weeks, ive lost 1st due to the prop denting the alloy end of the box, so now box is coming out and a new one going in ready for the new owner
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