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 Post subject: Re: Island Fugitive
PostPosted: Wed Mar 07, 2018 4:43 pm 
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Tough Mudder
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Joined: Tue Sep 06, 2011 1:25 am
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Location: Rotherham
Is there any room at all to space the MX5 flywheel away from the crank and then just use an MX-5 clutch plate with a VW spline popped in the centre?


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 Post subject: Re: Island Fugitive
PostPosted: Wed Mar 07, 2018 6:45 pm 
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Little Mudder
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Joined: Sun Jul 24, 2016 11:55 pm
Posts: 214
Good idea but had a measure and probably only a few mm before it fouls on the casing.

I was planning on just using a VW clutch plate as there is one the same dia 215mm.

Re- measured everything and also discovered that the longest VW shaft is 298mm not 300mm after a re-measure I figured out I need 29mm if I use that 298mm shaft :(

Looking at a few other things to do...

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 Post subject: Re: Island Fugitive
PostPosted: Wed Mar 07, 2018 10:51 pm 
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Little Mudder
Little Mudder

Joined: Sun Jul 24, 2016 11:55 pm
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Right so I just had a brain wave.

I get a new 298mm shaft, and chop off the clutch splined section off the old one. I also get a T2 shaft sleeve that does not have the reverse gear like a 002. I drill and thread a hole through the clutch section (not hardened in the middle!) and add a stud to duplicate the existing set up, screw in to gearbox, add 002 sleeve, screw in shaft and section, add sleeve. Voila extended shaft, all original parts no loss of strength.

Back of an envelope I had handy

Image

Also if my calculations are correct puts the smooth section of the VW shaft where the MX5 intermediate bearing and oil seal would be so If I can get a bush made I can still use the bearing. :mrgreen:

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 Post subject: Re: Island Fugitive
PostPosted: Fri Mar 09, 2018 9:33 pm 
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Little Mudder
Little Mudder

Joined: Sun Jul 24, 2016 11:55 pm
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... and would you believe it The General just happened to have a nice shiny T25 petrol input shaft which he generously donated to the cause! :D

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 Post subject: Re: Island Fugitive
PostPosted: Wed Mar 14, 2018 1:09 am 
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Little Mudder
Little Mudder

Joined: Sun Jul 24, 2016 11:55 pm
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Finally some progress! After over a month of research and head scratching I think I've cracked it.
Laser cut Ali plates are ordered, I know how to lengthen the shaft and have all the parts, I have a plan for using the MX5 intermediate bearing and oil seal on the VW shaft. I know how to attach the chopped MX5 bell housing to the plates - bolted up the test MDF plate and it all fits. :D

Image

Next up engine mounts, finish the exhaust then cooling and intake. I'll do the shaft and find a clutch plate when I pull it out for final weld up and paint.

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 Post subject: Re: Island Fugitive
PostPosted: Sun Mar 25, 2018 7:08 pm 
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Little Mudder
Little Mudder

Joined: Sun Jul 24, 2016 11:55 pm
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Beginning to look a bit more like an engine swap!

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Bought a used alloy rad off a Lexus with the outlets in the right place and conveniently built in expansion tank and twin fans so that's next when it arrives.

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 Post subject: Re: Island Fugitive
PostPosted: Wed Mar 28, 2018 11:50 pm 
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Little Mudder
Little Mudder

Joined: Sun Jul 24, 2016 11:55 pm
Posts: 214
Even got a fan club now...

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 Post subject: Re: Island Fugitive
PostPosted: Mon Apr 02, 2018 10:29 pm 
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Little Mudder
Little Mudder

Joined: Sun Jul 24, 2016 11:55 pm
Posts: 214
Oh dear.
Stripped it all out for weld up and paint only to discover that the diff gets in the way of sleeving the input shaft to extend it. Tried all sorts of combinations but even the best one brings the spline interface down to 14mm which is just not enough - esp bearing in mind the extra power going through it anyway. So as a last resort had to fork out around £160 for a Weddle 323mm version that should be exactly the right length.

Now that problem is (hopefully) solved I can finish up the adapter plates and the electrics..

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 Post subject: Re: Island Fugitive
PostPosted: Tue Apr 03, 2018 9:33 am 
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Baja Pro
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Location: Plymouth, UK
Bugger. Sometimes you just have to spend the cash.

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 Post subject: Re: Island Fugitive
PostPosted: Tue Apr 03, 2018 9:23 pm 
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Little Mudder
Little Mudder

Joined: Sun Jul 24, 2016 11:55 pm
Posts: 214
Yep. Anyway if it works I'll still be up a big chunk of cash over the Kennedy option. - Though the shaft cost does narrow that!
Lets hope for no more big surprises!

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