So the build begins

I am  :-)

It is just about tolerated - but only just !!

lhasadreams said

New bottom end back together, well as far as I can go without bits from the existing engine

New water pump?

pazwaa said

Your allowed car parts in the house???????????

Matt

That's probably why I'm single, my house is full of them!  

Yes Graham, I have another better quality new one to fit !!

Any way been progressing, bay painted, oil separator chopped to fit over the chassis leg so that the filter can sit on top :-)
Dual remote servo fitted, just started to plumb up - will get most of the pipe work done tomorrow if I can find my pipe cutter !!
But still waiting for some Goodridge hoses to arrive.
Hoping to get the new hubs, brakes and wheels fitted then.

I can then turn my attention to the 6 speed gearbox mod and getting the head etc fitted to the new block !!

Looking tidy Ade. 6-speed box! - Nice    

Cheers Andy :-)

Had the day off today and cracked on

The new servo is all plumbed in, just waiting for the goodridge hoses and then I can bleed it.

280mm disks are on complete with the Wilwood 4 pots that I bought years ago !!

New rack on as well as for some reason the old one had become very notchy.

I have fitted the Still Static coilovers to the front, they are wound right up at the moment and there is no engine/box weight.

New wheels on the front as the old ones will not clear the calipers.

A few pics

A bit more bank holiday work !!

So yesterday I tackled the 6 speed conversion of my O2j gearbox.
Original 5th gearing removed:

The old bits:

The new kit:

The new 5th and 6th fitted:

All done !!

lhasadreams said

So yesterday I tackled the 6 speed conversion of my O2j gearbox.
Original 5th gearing removed:

The old bits:

The new kit:

The new 5th and 6th fitted:

All done !!

hi mate where did you get the 6 speed gearbox kit from

http://www.eurotuning.cz/images/image/en/optimizing/conversion_kit.html

lhasadreams said

http://www.eurotuning.cz/images/image/en/optimizing/conversion_kit.html

thanks i'll be looking to do this one day did you have to change the gear shifter too ?

No, it is a standard O2j one with the shorter Lupo GTI cables. I do have a Diesel Geek short shift kit at the shifter tower end as well (worth every penny).

The 5th gear selector fork in the gearbox already has the provision to select 6th if it was allowed to move in that direction - that is the fork that is removed and replaced with one from the kit that has an extension to allow it to reach the new 5th/6th synchronising hub.

Good work Ade - gearboxes scare me!!  

Seems a good price too

big respect for modding the gearbox, i'm with andy, looks scary  

matt

Cheers guys - it was pretty straight forward in the end - although no presses were involved, just a small puller to get one of the gears off. Compared to most the price was brilliant - this did put me off at one point and that it was coming from the Czech Republic. However over on the diesel forums they rave about the kit with several people putting over 30K miles on them, and we all know hoe much torque a diesel engine puts out !

Hairyarse said

Good work Ade - gearboxes scare me!!  

Your not the only one, I've had a play with a few boxes over the years and I'm still not happy doing them!    I will master them one day!

Looks like a cracking job so far Ade, keep up the good work mate  

Thanks guys.
Took a couple of days off last week to build up the engine - just got her back in :-) !!!!!

Oooo now that looks nice Ade  

Thinking about doing the 6 gear thing myself  Some job Ade, lots of respect from the better side of the wall.

Oh and 🇮🇹