Alternative gearbox for X1/9 from VW, Audi (WAG group)

[Janis]

And Yes, my X has some close friendship with rust

 

[Dr.Jeff]

As you said, that cut in the frame horn could be a lot less. But that's expected when figuring out a new application for the first time.

If I recall correctly, even that amount of clearancing (in the frame) was to allow the transmission to mount closer to the left so that the original axles could align with the VW CV joints? If I'm right, that cut is a very small sacrifice to make in order to NOT need custom made axles. And it is a LOT less cutting overall than with the Honda swaps.

For the inspection to look more stock be sure to fill things like these

 

[Janis]

Yeah, saw again today that VW sign undeneath
I’ll make one with Bertone or Fiat logo.
Cltuch slave cylinder won’t be in eyesight for inspectors.

 

[Janis]

19mm hexagon socket needs D28mm space and there is not so much space, that would mean that base plate would have to be made from seperate pieces.

So allen bolts might be best solution.

Will check when be at tha car another option also as Akos did- without sinking bolts in adapter, but make cutouts in bellhousing.

 

[Dr.Jeff]

Can’t find any M12x1.25 countersink bolts.

M12X1.25 Extra Fine Allen Socket Flat 12.9 + 10.9 DIN 7991

Bel-Metric sells metric hardware & specialty automotive supplies nationwide. Visit our website to purchase metric fasteners, nuts, bolts, Time-Sert kits & more.

belmetric.com

 

[Bjorn Nilson]

You removed meat on bellhouse to make room for the starter. Is the starter on the gearbox side? That this mean that you wont use X1/9 starter and flywheel?

 

[Janis]

VW has starter on gearbox side- see in picture.

I will use X flywheel and starter.

 

[Janis]

In this picture You can see wheee is VW’s starter placed and where is X’s.

Boxes aligned by input shaft and stub shafts.

 

[Bjorn Nilson]

So it is just for making the VW box look original Fiat then. Will require a lot of welding to restore rigidity that has been lost in the bellhouse.
Interesting project Janis, l am looking forward to se the final result.

 

[Janis]

Will tack it and testfit gearbox with engine together tomorrow or on the next week.

Also might modify it with more equal crossection, because it defintely doesn’t look that could be from factory like that

 

[Ulix]

Janis, there is no way to avoid cutting the gearbox by adapting the VW starter or mounting the X1/9 starter on the gearbox side (would need to revers direction of starter)?

 

[Janis]

There might be.
I just didn’t have VW starter motor to check that, and neither wanted extra thing to think about.

One thing I still can do - check distance from input shaft to center of starter shaft if that is different on X and VW then it won’t work.

Custom flywheel offcourse would solve a lot, that fits X’s cranshaft.

*That hole that I have made in bellhouse is a lot bigger than actually needed - will make photo of it with starter mottor added on next week.

**Not much free time lately because I have to be also the manager of project manager

 

[Janis]

Here you can see starter positioned in VW box.

 

[Janis]

Welded patch.
Without test fit with drivetrain, I hope it will be ok
Later will repaint whole engine bay, so that patch doesn’t pop out visually

 

[Bjorn Nilson]

Ouch! You've lost a lot of rigidity there. I think you should box it on top, or veld on a thick plate in a standing position to reinforce it.

 

[Janis]

Ouch! You've lost a lot of rigidity there. I think you should box it on top, or veld on a thick plate in a standing position to reinforce it.

I should, but it is definitely more rigid than before - it was made of half rust

 

[Janis]

This would be solution, but I had imaginar rush today, and forgot about it, but still can add a section

 

[Dr.Jeff]

If the metal used to fill the cut-out area (the "patch") is thicker than the original metal then it will be stronger and provide some added structural support. Also you could still add the higher arch on top, as you illustrated in post #97. That can be done over what's already there if you think the frame needs more strength.

 

[Janis]

Today got a little too big (228mm ) clutch disc for tests.

Can’t clarify that all 02J boxes have same input shaft parameters, but my has 28 splines.

This 190mm might be the one to use if 190mm system is used. But it might interfere with something. There a lot of biger sizes available.

If it will be reasonably possible to use pads from my old (500km) X’s clutch disc in combination with center part from 228mm VW disc I got, then I’ll do it to avoid resurfacing/matching and extra costs there..
This is VW 228mm disc I got today:

This is Valeo disc I have in X now.

 

[Janis]

(This post is not what I thought I had typed but am not deleting or editing it otherwise further comments will seem wierd)

Or that 228 mm VW clutch disc I got can’t be used with double mass flywheel because it doesn’t have springs?