The Brick-yard Homepage Brickwerks
Forum Home Forum Home > The Brickyard > The Bus Park
  New Posts New Posts RSS Feed - T3 Doka "project"
  FAQ FAQ  Forum Search   Events   Register Register  Login Login

T3 Doka "project"

 Post Reply Post Reply Page  123 5>
Author
Message Reverse Sort Order
Lits View Drop Down
Groupie
Groupie
Avatar

Joined: 08 Jun 10
Location: W.Yorks
Status: Offline
Points: 119
Post Options Post Options   Thanks (0) Thanks(0)   Quote Lits Quote  Post ReplyReply Direct Link To This Post Topic: T3 Doka "project"
    Posted: 25 May 20 at 20:19

I was hoping to go to the T3 bus meet as its the first year it hasn't clashed with VW festival at harewood House! But covid's fucked that up! Angry



Don't start what you can't finish!
Back to Top
Lits View Drop Down
Groupie
Groupie
Avatar

Joined: 08 Jun 10
Location: W.Yorks
Status: Offline
Points: 119
Post Options Post Options   Thanks (0) Thanks(0)   Quote Lits Quote  Post ReplyReply Direct Link To This Post Posted: 25 May 20 at 20:16


Are they ever finished? LOL


Don't start what you can't finish!
Back to Top
rowlesy View Drop Down
Vanorak
Vanorak
Avatar
murdered the murderwagen

Joined: 09 Oct 05
Location: up unit!
Status: Offline
Points: 6463
Post Options Post Options   Thanks (0) Thanks(0)   Quote rowlesy Quote  Post ReplyReply Direct Link To This Post Posted: 15 May 20 at 10:36
finished yet?

UberFukz broke another!       sucky sucky five dollah!

always out numbered never out gunned!    RWS welding 07846 380 467 (worcs)
Back to Top
booted View Drop Down
Vanorak
Vanorak
Avatar

Joined: 13 May 07
Location: Luton
Status: Offline
Points: 2665
Post Options Post Options   Thanks (0) Thanks(0)   Quote booted Quote  Post ReplyReply Direct Link To This Post Posted: 04 May 20 at 17:36
photobuckets useless now they want to charge an arm and leg for anything useable
Back to Top
Lits View Drop Down
Groupie
Groupie
Avatar

Joined: 08 Jun 10
Location: W.Yorks
Status: Offline
Points: 119
Post Options Post Options   Thanks (0) Thanks(0)   Quote Lits Quote  Post ReplyReply Direct Link To This Post Posted: 26 Mar 20 at 20:23

Fuck me, realised why I stopped putting pictures on Angry

There must be an easier alternative to photo bucket?


Don't start what you can't finish!
Back to Top
Lits View Drop Down
Groupie
Groupie
Avatar

Joined: 08 Jun 10
Location: W.Yorks
Status: Offline
Points: 119
Post Options Post Options   Thanks (0) Thanks(0)   Quote Lits Quote  Post ReplyReply Direct Link To This Post Posted: 26 Mar 20 at 20:20
Don't start what you can't finish!
Back to Top
Lits View Drop Down
Groupie
Groupie
Avatar

Joined: 08 Jun 10
Location: W.Yorks
Status: Offline
Points: 119
Post Options Post Options   Thanks (0) Thanks(0)   Quote Lits Quote  Post ReplyReply Direct Link To This Post Posted: 26 Mar 20 at 17:18

Only 5 years 4 months since last Post!!!


Don't start what you can't finish!
Back to Top
koendd View Drop Down
Not Quite Newbie
Not Quite Newbie


Joined: 06 Jul 12
Location: Belgium
Status: Offline
Points: 23
Post Options Post Options   Thanks (0) Thanks(0)   Quote koendd Quote  Post ReplyReply Direct Link To This Post Posted: 04 Dec 14 at 22:09
cracking job you're doing there!
vw t3 1.6td
Back to Top
Lits View Drop Down
Groupie
Groupie
Avatar

Joined: 08 Jun 10
Location: W.Yorks
Status: Offline
Points: 119
Post Options Post Options   Thanks (0) Thanks(0)   Quote Lits Quote  Post ReplyReply Direct Link To This Post Posted: 30 Nov 14 at 20:33
I'll start doing some trig, work out the height I need to make my ramps!   

I thought making adaptor plate for gearbox/bellhousing was easier to do, especially in keeping the two bolt pattens lined up. Also a spacer for flywheel would have been required I presume? Or do you mean machine bellhousing down 10mm to allow for adaptor like the flipped audi gearbox conversions have been doing?

Don't start what you can't finish!
Back to Top
Zebedee View Drop Down
Vanorak
Vanorak
Avatar

Joined: 08 Jan 09
Location: Maryport
Status: Offline
Points: 1121
Post Options Post Options   Thanks (0) Thanks(0)   Quote Zebedee Quote  Post ReplyReply Direct Link To This Post Posted: 27 Nov 14 at 12:18
Two wheels on one side on drive up ramps to tilt pickup 15 degrees so drain hole is at bottom.Wink

How come you made the adapter for between the gearbox and bellhosing instead of the bellhousing and engine?



Edited by Zebedee - 27 Nov 14 at 12:19
Back to Top
max and caddy View Drop Down
Vanorak
Vanorak
Avatar

Joined: 12 Dec 09
Location: Lancaster..uk
Status: Offline
Points: 4866
Post Options Post Options   Thanks (0) Thanks(0)   Quote max and caddy Quote  Post ReplyReply Direct Link To This Post Posted: 26 Nov 14 at 18:36
Could always tip the truck up a bit..
Back to Top
Lits View Drop Down
Groupie
Groupie
Avatar

Joined: 08 Jun 10
Location: W.Yorks
Status: Offline
Points: 119
Post Options Post Options   Thanks (0) Thanks(0)   Quote Lits Quote  Post ReplyReply Direct Link To This Post Posted: 23 Nov 14 at 21:41
Yes Max and caddy the drain plug is a bit of a compromise, I did think about drilling and tapping my own in the casing but then thought better of it. 

I'll jump the gearbox oil change at a later date or when the box explodes!!! 

But it is definitely a cost effective way to install an upright inline 4 (so far). Wink


Don't start what you can't finish!
Back to Top
Lits View Drop Down
Groupie
Groupie
Avatar

Joined: 08 Jun 10
Location: W.Yorks
Status: Offline
Points: 119
Post Options Post Options   Thanks (0) Thanks(0)   Quote Lits Quote  Post ReplyReply Direct Link To This Post Posted: 23 Nov 14 at 21:25
I can't find the pictures of the bay painted Angry I'll keep searching.

My plan was to lift engine into the bay bolt it to the reinstalled gearbox, then decide how I was going to make the mounts. 

We do have an engine hoist somewhere but I went for a more scrapheap challenge approach LOL
















































































Don't start what you can't finish!
Back to Top
Lits View Drop Down
Groupie
Groupie
Avatar

Joined: 08 Jun 10
Location: W.Yorks
Status: Offline
Points: 119
Post Options Post Options   Thanks (0) Thanks(0)   Quote Lits Quote  Post ReplyReply Direct Link To This Post Posted: 23 Nov 14 at 21:11
With the engine out I cleaned up the engine bay a bit removed a bit of surface rust, 







































2 bits that needed a little piece welding in.














































































I painted the bay in zinc phosphate black.



Don't start what you can't finish!
Back to Top
max and caddy View Drop Down
Vanorak
Vanorak
Avatar

Joined: 12 Dec 09
Location: Lancaster..uk
Status: Offline
Points: 4866
Post Options Post Options   Thanks (0) Thanks(0)   Quote max and caddy Quote  Post ReplyReply Direct Link To This Post Posted: 21 Nov 14 at 17:24
Good stuff...other than the oil drain plug no longer being at the bottom and as long as everthing is lined up perfect this is a good solution to use a standard box on a upright engine I reckon.
Back to Top
Lits View Drop Down
Groupie
Groupie
Avatar

Joined: 08 Jun 10
Location: W.Yorks
Status: Offline
Points: 119
Post Options Post Options   Thanks (0) Thanks(0)   Quote Lits Quote  Post ReplyReply Direct Link To This Post Posted: 16 Nov 14 at 21:16
Next I stripped engine from the gearbox, drained all the gearbox oil and cleaned up the casing a bit.
Then I offered the adaptor plate to the gearbox and located it on the dowels.







































I made some locating dowels for the rotated bellhousing out of some 12mm bolts turned down.







































I used a new gasket and the m8 vee head bolts to bolt plate on. (I did use a couple of hex heads where bellhousing didn't cover).







































The bellhousing bolted up ok too, I used a new gasket on this side aswell. Before fitting the bellhousing I put a new shaft seal in.







































In theory this now means the engine will bolt up at 15 degrees.








































Don't start what you can't finish!
Back to Top
Lits View Drop Down
Groupie
Groupie
Avatar

Joined: 08 Jun 10
Location: W.Yorks
Status: Offline
Points: 119
Post Options Post Options   Thanks (0) Thanks(0)   Quote Lits Quote  Post ReplyReply Direct Link To This Post Posted: 13 Nov 14 at 21:46
Now I had all the bits/bolts etc to attach adaptor plate to gearbox, bellhousing to adaptor plate and engine to bellhousing I decided to go for taking engine out of doka. I knew it wouldn't be done in just a couple of days like when using all diesel bits because I'd have to fabricate some kind of mounts to allow for upright engine. And there is always some unforseen problems.

Old 1.9 DG 
















































































It wasn't bad at all disconnecting pipes, wiring and mounts. Only one bolt seized on engine mounting bar. Smile I did butcher the exhaust a bit but it was in a bad way.








































One hot tip is Jack T3 up high enough to get engine out easily.














































































Ha Ha there was no going back at this point! Ermm


Don't start what you can't finish!
Back to Top
Lits View Drop Down
Groupie
Groupie
Avatar

Joined: 08 Jun 10
Location: W.Yorks
Status: Offline
Points: 119
Post Options Post Options   Thanks (0) Thanks(0)   Quote Lits Quote  Post ReplyReply Direct Link To This Post Posted: 13 Nov 14 at 20:51
Yes the input petrol input shaft needs shortening by 12ish mm to be used with the diesel bellhousing, I was hoping that would mean only a few mm off because of the adaptor thickness but it needs removing from the unsplined spigot end. The extra adaptor plate thickness needs adding to the splined end which goes into the gearbox.








































Shortened input shaft








































The splined joining collar also needed extending to make sure it stayed central on both shafts and didn't slip towards the gearbox shaft reducing how much of the splined part of the input shaft it was on. 
(I am confused after that statement and I did it!LOL) hopefully pics will make it clear.















































































10mm spacer turned and tigged onto collar. Not sure about spacer staying welded to hardened collar! Ermm








































This is the collar with its spacer attached and also the input shaft with its spacer screwed on.
I used a bolt cut down and drilled and tapped the 10mm spacer for the input shaft. I struggled finding the right bolt, in the end the closest I could find was m7 x 1 (that common size LOL)







































The input shaft has the collar slid on then it is screwed down onto the output shaft of the gear box down here:







































The input shaft is screwed down till the 2 shafts touch then with the splines lined up the collar is pushed down till the cipclip which holds it in position can be put back in its groove.



Don't start what you can't finish!
Back to Top
rowlesy View Drop Down
Vanorak
Vanorak
Avatar
murdered the murderwagen

Joined: 09 Oct 05
Location: up unit!
Status: Offline
Points: 6463
Post Options Post Options   Thanks (0) Thanks(0)   Quote rowlesy Quote  Post ReplyReply Direct Link To This Post Posted: 13 Nov 14 at 17:32
yes mate by whatever thickness the adaptor plate is. or space behind the cluich if your starter doesnt reachout far enuf. 
UberFukz broke another!       sucky sucky five dollah!

always out numbered never out gunned!    RWS welding 07846 380 467 (worcs)
Back to Top
Lits View Drop Down
Groupie
Groupie
Avatar

Joined: 08 Jun 10
Location: W.Yorks
Status: Offline
Points: 119
Post Options Post Options   Thanks (0) Thanks(0)   Quote Lits Quote  Post ReplyReply Direct Link To This Post Posted: 12 Nov 14 at 22:19
Back to the adaptor plate, I measured the centre hole in the sacrificial bellhousing then drilled a hole that size in the metal plate and marked the centre lines of this hole to help me when rotating it 40 degrees. I used a piece of round bar to keep the plate and bellhousing in line.

I marked and drilled through the first set of holes with the bellhousing in the "vertical" position, and also drew round outside edge - thats the black marker line. Then using my protractor LOL  I marked the centre line at 40 degrees and turned the bellhousing onto centre line. I repeated the drilling of the holes in new position and again drew round it.

The vertical set of holes are the bolts which hold the adaptor to the gearbox, any of these holes which fell within the rotated bellhousing position needed to be vee head bolts to make them flush fitting.
 
Also the there are 2 dowels on the gear box to help location, which are the middle holes.

The holes for the diesel bellhousing at 40 degrees had to be drilled and tapped m8.

The cut out is to allow for clearance of the big differential gear? Confused 

I shaped the outer edge of the adaptor with cutting, grinding and flapper disks.








































Overall it wasn't as complex as I thought it was going to be, but the addition of a 10mm plate inbetween gearbox and bellhousing meant I would have to modify the input shaft and the splined collar which joins input shaft and gearbox output shaft? 






Edited by Lits - 12 Nov 14 at 22:21
Don't start what you can't finish!
Back to Top
 Post Reply Post Reply Page  123 5>
  Share Topic   

Forum Jump Forum Permissions View Drop Down

Forum Software by Web Wiz Forums® version 12.01
Copyright ©2001-2018 Web Wiz Ltd.

The WebThis site