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 Post subject: Re: Island Fugitive
PostPosted: Fri Jan 05, 2018 10:15 pm 
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Little Mudder
Little Mudder

Joined: Sun Jul 24, 2016 11:55 pm
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Right. Bugger it. It's not sandrail weather and it's time the 1960's got updated. Had a good look over the MX5 wiring loom, thought about cooling and after 2 whole miles of IRS testing pulled out the VW engine (10 mins) for good.
Built a wheely stand for the MX5 engine and started work on joining it to the bus box.

Image

Milled the half a transmission case flat. Now to figure out a way to join it to a VW shaped plate without distorting it..
Image

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 Post subject: Re: Island Fugitive
PostPosted: Sat Jan 06, 2018 10:36 pm 
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Little Mudder
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Bolted on the half transmission and hoisted it up to take a look - all fits in the space, might not have to do any modifications :thumbup:.

Image

Gives me a good idea of the extra structure for the engine mounts, I have some 50x25 box that for me looks as aesthetic as tube whilst being easier to bolt stuff too.

Exhaust will take some thought...

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 Post subject: Re: Island Fugitive
PostPosted: Sun Jan 14, 2018 3:15 pm 
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Little Mudder
Little Mudder

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Exhaust mock up

Image

Going to re-use the MX5 small silencer.

Not figured out how to attach the big ali joining plate to the MX5 half yet. Expert opinion suggests that TIG welding might distort the bearing carrier which will cause a whole load of pain.

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 Post subject: Re: Island Fugitive
PostPosted: Thu Jan 25, 2018 10:01 pm 
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Little Mudder
Little Mudder

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So not the most exciting update but after a few false starts I got the exhaust routed over rather than under, only needing one extra part (yes that is a bit of waste pipe!)

Image

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I'll tack up a few exhaust mounts but won't fully weld until all finished as there is a lot of other stuff to go in - Engine mounts/cage next whilst I work on the engine/transmission join

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 Post subject: Re: Island Fugitive
PostPosted: Mon Jan 29, 2018 1:22 am 
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Little Mudder
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Tacked up the first part of the engine cage:

Image

Image

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 Post subject: Re: Island Fugitive
PostPosted: Wed Feb 07, 2018 10:10 pm 
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Little Mudder
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Back to the adapter plate, I used a cheap scanner and CAD to make a template for the laser cutters by overlaying the scanned images of the two parts.
Getting it cut in 1mm steel to check it fits before the 23mm Ali needed to accommodate the diff stick out.

Image

Image

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 Post subject: Re: Island Fugitive
PostPosted: Thu Feb 08, 2018 12:49 am 
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Little Mudder
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Getting there mate. Have to catch up soon. I'm hoping to get some more glass from Vestas enough to do 6 seats (for me, you and Dave) and some other stuff. If you fancy giving us a hand to make them. Can we use your plastic seat as the mold? :D I was hoping to infuse them but doubt i can use the factories vacuum pumps. :lol:


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 Post subject: Re: Island Fugitive
PostPosted: Thu Feb 08, 2018 1:51 pm 
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Little Mudder
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Sounds like a great plan to me! Just let me know.

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 Post subject: Re: Island Fugitive
PostPosted: Wed Feb 28, 2018 4:41 pm 
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Little Mudder
Little Mudder

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Need to get MX5 shaft welded to VW shaft

Image

Spoken to two separate recommended motorsport engineering shops, one said "sure, do it all the time no problem", the other said "nope, fail, disaster, need a new shaft making for £££" - however shop 1 has not been heard of since...

Sooo..I am investigating throwing away all my work so far and starting again and making a Franken clutch so I can just use the VW shaft.

The VW clutch plate is 200mm and the 1.8L MX5 engine clutch is 215mm - consequently the MX5 flywheel and ring gear won't fit in the VW bell housing. However, I have discovered it is a known mod to put the 200mm clutch off a 1.6L on the 1.8L engine as a poor man's lightened flywheel, so if that would fit in the bell housing, a VW plate looks like a standard item, and if I can get the throw out bearing to work...

edit - rats, flywheel is same diameter :(

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 Post subject: Re: Island Fugitive
PostPosted: Thu Mar 01, 2018 10:13 am 
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Baja Pro
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The VW CT engine uses a 215mm clutch - it's a stealth upgrade that most people don't know about.

https://www.coolairvw.co.uk/Item/Shop_b ... gines.html

I don't know if that helps...

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