BiAS
Club Retro Rides Member
Insert witty comment here
Posts: 2,231
Club RR Member Number: 147
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Last Edit: Oct 10, 2010 22:53:52 GMT by BiAS
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craig
Posted a lot
Posts: 1,029
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I'd make some cast plugs up in the lathe, weld them in and skim the weld back in the lathe after clocking the face to get it square. I'd vote Tig too as Mig always seems hard.
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MrSpeedy
East Midlands
www.vintagediesels.co.uk
Posts: 4,789 
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Flywheels are generally made from chilled iron, which makes them tougher than grey cast iron. Welding should be done in a temp controlled atmosphere, ie oven, to evenly raise and lower and control the temp before, during and after welding, which is preferably done with a gas torch. NEVER with the mig.
Tbh, given the loads involved i personally would suggest you give the job to a pro or find another flywheel that fits your engine. (i can weld cast iron and i wouldn't attempt it!)
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get one to fit the job, I'm not a fan of redrilling flywheels, if it were just slotting the holes slightly then yes, but welding and redrilling something thats going round a 7k rpm and weighing 15kilos has enough energy to rip your feet clean off. not worth the saving is it  |
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Is it sad that I knew that was a flywheel from an F20 gearbox?
Take it to an engineers/fabricators, and get them to do it.
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if you have to have it done, get a pro to do it.
i cant stress enough how important it is NOT to feck something like this up !
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if the bolt holes arnt going to cause any problem i would leave them as they are
if you weld it up there is a good chance you could distort the flywheel
and you will also be adding weight (not much)
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I'd agree with stuartrf, not that I know much of these things.. I'd be worrying about making the flywheel unbalanced, but the unevenly spaced holes made me confused. I was about to write something about at least making the static balance right by building a rig and remove some weight.
And yes, these things are important not to bodge (at least not too extremely) I've heard too much about home lightened ones exploding, sending shrapnel into the car, slicing off people's feet etc. They're still a very popular mod to no-budget rally cars here though.
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Last Edit: Oct 9, 2010 13:48:47 GMT by dude
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conrad
Posted a lot
Here to fix your cabin.......
Posts: 1,678
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be adding weight (not much) "not much" could still cause a nasty accident if it caused it to be unbalanced, specially since it'll be spinning at high speed for long periods |
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It's why Don Garlits designed the first rear engined dragster when the exploding flywheel cost him some toes .In all honesty I'd have been more worried about my jewels resting on the diff housing. Photo of the explosion below. Apparently the young guy circled also lost an arm:(  |
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I have seen first-hand the effects of a home-modded flywheel letting go during a trackday.....Lets just say the passenger in the Nova was damn lucky everything exited the car forwards instead of towards the cabin.
Flywheels are one thing I really think best left alone, or at least modded by someone professional who has proven knowledge of what they are doing.
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1986 Panda 4x4.
1990 Metro Sport.
1999 Ford Escort estate.
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v8ian
Posted a lot
Posts: 3,832
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Would you weld up a brake disc?  ??, probably not, but a flywheel takes a hell of a lot more punishment than disks in the way of shock loading |
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Atmo V8 Power . No slicks , No gas + No bits missing . Doing it in style.
Austin A35van, very different------- but still doing it in style, going to be a funmoble
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carmad
Posted a lot
Posts: 2,002
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Hold on before you go drilling fly wheels
I might have your answer
You need 8 holes for a xe or let engine
But your fly wheel only has 6 was it originally intented for a c20 ne ?
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V-Force
Part of things
I like Hondas.
Posts: 846
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Oct 10, 2010 20:22:09 GMT
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This is what happens when a flywheel fails:
Aftermath:
So it's proabably not a good idea...
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1999 Impreza WRX typeR STI Version 5 Limited
1999 Civic VTi-S Aerodeck
2005 Bora TDI daily
Several other 90s Hondas (shhh they're sleeping)
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BiAS
Club Retro Rides Member
Insert witty comment here
Posts: 2,231
Club RR Member Number: 147
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Oct 10, 2010 21:34:56 GMT
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Hold on before you go drilling fly wheels I might have your answer You need 8 holes for a xe or let engine But your fly wheel only has 6 was it originally intented for a c20 ne ? Don't worry, I'm not going to weld it up and re-drill it, thanks for the advice all. In my defence it was quite late when I started this and I'd been in the garage all day and all night (that's my excuse and I'm sticking to it) carmad - Talk to me, I'm interested, I've got a pot type XE flywheel on at the moment and I think that I can alter where the clutch slave sits to make it work but I'm always interested in alternative answers  What do I need? |
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bmw156
Part of things
Posts: 796
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Oct 10, 2010 21:53:06 GMT
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whats the combo your trying to use... or what are you trying to do...
there should be an off the shelve answer for you, as its such a common answer. and if your trying something new at this stage in the engines life it must have no gain lol.
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Oct 10, 2010 22:26:34 GMT
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Hold on before you go drilling fly wheels I might have your answer You need 8 holes for a xe or let engine But your fly wheel only has 6 was it originally intented for a c20 ne ? Don't worry, I'm not going to weld it up and re-drill it, thanks for the advice all. In my defence it was quite late when I started this and I'd been in the garage all day and all night (that's my excuse and I'm sticking to it) carmad - Talk to me, I'm interested, I've got a pot type XE flywheel on at the moment and I think that I can alter where the clutch slave sits to make it work but I'm always interested in alternative answers What do I need? from what I can work out youre trying to fit a 6 bolt 8v flat face flywheel to an XE/LET crank which has 8 bolts. If thats correct - the easiest solution would be to find an early XE flywheel which is very similar if not the same to the 8v one you have and has 8 holes. That's what I have done on my LET to ditch the heavy pot type one. |
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Last Edit: Oct 10, 2010 22:27:27 GMT by brettsri
87 Mk2 Cavalier SRi Turbo
89 Mk3 Cavalier SRi V6
90 Cartlon GSi3000 24v (Lotus Rep)
90 Senator CD 24v
99 Omega 3.0 MV6
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BiAS
Club Retro Rides Member
Insert witty comment here
Posts: 2,231
Club RR Member Number: 147
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Oct 10, 2010 22:49:32 GMT
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^^Yep, XE onto Frontera petrol gearbox, Frontera originally has a flat 6 bolt flywheel, XE has a flywheel that's the same thickness but has the clutch recessed into it by an inch, meaning that the release bearing and arm need to sit an inch further forward.
So it's the early XE flywheel that'll sort it out then?
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Oct 10, 2010 23:04:05 GMT
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I had an XR4x4 that had snapped its front prop shaft, thats probably a tenth of the weight and still managed to take a large chunk out of the gearbox and bend the floor.
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Volvo back as my main squeeze, more boost and some interior goodies on the way.
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rod
Posted a lot
Posts: 1,953
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Oct 11, 2010 15:52:45 GMT
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The prop in my Amazon let go at about 80 mph . Some serious dents in the prop tunnel as it thrashed around!
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[*]
??, probably not, but a flywheel takes a hell of a lot more punishment than disks in the way of shock loading
