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Damon Cornish
Tinkerer
Qld
V8

Posts: 82
Reg: 03-2009

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Sunday, July 20, 2014 - 06:11 pm, by:  Damon Cornish (Boz) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)


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James Buchan
Goo Roo
Vic
vvt-i turbo

Posts: 1821
Reg: 10-2008

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Sunday, August 17, 2014 - 07:46 pm, by:  James Buchan (Jrbuch) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Looking good :-) Any more updates?
Damon Cornish
Tinkerer
Qld
V8

Posts: 83
Reg: 03-2009

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Sunday, August 24, 2014 - 11:56 am, by:  Damon Cornish (Boz) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Been pretty slow going lately. I only really spend 1/2 a day a week in the shed. I've struck a few more hurdles but think I almost have the plans in place.
The new balancer and s/c pulleys turned up. I had to skim the id of the balancer out a bit to achieve a decent interference fit then heated it to 105degrees C with an induction heater to get it to fit (Its not coming off in a hurry that's for sure).
Then fitted the low boost pulley to the crank. The first issue I have to sort is the snout pulley and the crank pulley are 3mm offset (Grr!) I could make a spacer easily enough but this will annoy me for sure. Next test the high boost pulley......No good. The hyd fan pump has to go, I didn't really want to do this as I was pretty happy with the fan.
So after a bit of research I got a hold of a Lincon mk8 fan motor and as you can see it looks like it may have been made for the task. I'll have to create a shaft adapter or alternately procure a lincon fan 18" compared to our 18.5". Not sure which way to go there.

Next is throttle actuation and throttle bodies. you have to be a bit careful when buying stuff from ebay ha ha. the oversized v6 commodore throttle bodies were no good (they didn't snap back like they should have and they were heavy to open) so a mate went to the wreckers for me and grabbed a couple of used ones that we can clean up and the work well. I will probably have to forgo cruise control at least initially due to clearance issue and lets face it it'll probably be to expensive to take on long trips once finished anyway.
OK so photos....

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Damon Cornish
Tinkerer
Qld
V8

Posts: 84
Reg: 03-2009

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Sunday, August 24, 2014 - 11:59 am, by:  Damon Cornish (Boz) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)


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Damon Cornish
Tinkerer
Qld
V8

Posts: 85
Reg: 03-2009

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Sunday, August 24, 2014 - 12:02 pm, by:  Damon Cornish (Boz) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)


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Damon Cornish
Tinkerer
Qld
V8

Posts: 86
Reg: 03-2009

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Sunday, August 24, 2014 - 12:04 pm, by:  Damon Cornish (Boz) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)


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Clayton Carlyle
TryHard
NSW
v8 soarer twin turbo

Posts: 320
Reg: 04-2009

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Sunday, August 24, 2014 - 10:16 pm, by:  Clayton Carlyle (Clayton) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Nice work Damon, pulleys look the bizz!
Allan Langford
Goo Roo
Vic
UZZ31

Posts: 1252
Reg: 05-2010

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Monday, August 25, 2014 - 06:43 pm, by:  Allan Langford (Allan) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

why did you remove the hydro fan? it works really well!

I would not be running a single electric fan you would be much better off with a set of AU falcon (or similar) fans spinning up a single large fan is going to put ALOT of electrical load on an already hard working alternator
Damon Cornish
Tinkerer
Qld
V8

Posts: 87
Reg: 03-2009

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Monday, August 25, 2014 - 08:36 pm, by:  Damon Cornish (Boz) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Removing the hyd fan wasn't the first option. However I will be running 25ish psi at some point in the future and that means a large crank pulley. Unfortunately the OD of the large crank pulley and the OD of the hyd fan intersect.

I'm not throwing the fan motor away and if I decide to go dry sump in the future will I might add a section to the pump and refit it.

I looked at the au and ef-el fan set ups but to be honest, I couldn't fit them with my w/a reservoir. Also I don't like the cheap plastic look of the majority of the aftermarket radiator fans. The lincon motor originally ran an 18" fan ( ours are 18.5") and pulled 4600cfm which is I think pretty impressive although I haven't been able to find any figures on what ours put out.
Given it will draw a consistent 30amps on low and 50-60amps on high speed but I'm running the pov pack as far as acc go , so I'll give it a crack and see how it works out.
Scott Vim
DieHard
Vic
Soarer (1uz) Chaser (1jz)

Posts: 982
Reg: 12-2010

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Monday, August 25, 2014 - 08:47 pm, by:  Scott Vim (1uz1jz) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

I hate the sound of an electric fan though.
Damon Cornish
Tinkerer
Qld
V8

Posts: 88
Reg: 03-2009

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Tuesday, August 26, 2014 - 08:09 pm, by:  Damon Cornish (Boz) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Not sure noise is going to be a big consideration, it'll be sitting very close to a belt driven supercharger ;-)
Allan Langford
Goo Roo
Vic
UZZ31

Posts: 1254
Reg: 05-2010

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Friday, August 29, 2014 - 11:06 am, by:  Allan Langford (Allan) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

flip the hydro fan pulley and run it off the back of the toothed belt / make a toothed pulley for it?
Damon Cornish
Tinkerer
Qld
V8

Posts: 93
Reg: 03-2009

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Wednesday, January 07, 2015 - 10:12 pm, by:  Damon Cornish (Boz) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Haven't made a lot of progress lately but thought I'd update the thread so...
Sent the HTD pulleys back, as when they arrived there was an offset between the drive an driven pulleys! 3 or 4mm, or the same depth as the spacer step on the drive pulley. Face palm.

I got the t56 conversion Ben Williams was selling from Callum, so I've pulled the auto and fitted the clutch master cylinder and pedal. What a pain in the arse that was, done now thank goodness. Purchased a brake pedal and clutch and brake pedal rubbers from ayamaya.
The kit was sent in 3 pieces, 2 turned up xmas eve.
I collected the gearbox today, got home and found that at some time during its travel north it's been dropped and its bashed a mount in and holed the housing.....so it's completely f#%ked!!
I've contacted E-go and we'll see how that pans out but I'm not holding my breath.
I've got a ve tr-6060 in the shed but I'm not sure if it can be modified to fit or not. Ill ring mal wood auto tomorrow and find out.

Flex fuel sensor kit turned up today as well.
I've been thinking about how to actuate the throttle bodies and have a plan coming together. The modified holden v6 throttle bodies that I had didn't feel right, they were a bit stiff so a mate went and grabbed a couple from the wrecker for me. I cut the linkages of them and it turns out the have 8mm shafts so that's a huge win and I brough a couple of lever arms, a couple of tie rods and a bell crank. Also spent a night with filed and die grinder removing some of the outside castings (for aesthetics really)
Will post some photos on the weekend.
Damon Cornish
Tinkerer
Qld
V8

Posts: 94
Reg: 03-2009

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Wednesday, January 07, 2015 - 10:16 pm, by:  Damon Cornish (Boz) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

I had a look at flipping the hydro pulley but there's no room with the large HTD pulley on. It's a bit hard to see in the photos but it would be like the Olympic rings.
Clayton Carlyle
TryHard
NSW
v8 soarer twin turbo

Posts: 353
Reg: 04-2009

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Thursday, January 08, 2015 - 09:09 am, by:  Clayton Carlyle (Clayton) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Hey Damon, got any pics of the whole? You could possibly get it welded up but I would use the Tr6060 as it's a lot stronger & will shift smoother, the problem is making a shifter to come through in the right spot. I've been researching a design to put one in my Supra with is exactly the same as putting it in a Soarer.
That conversion kit looked a tad unfinished to me. The shifter is useless like that & won't come through where you need it, that's why they've dodged up that shifter surround to make it work. I would buy a new shifter surround from Toyota, they're about $40.00. You need to get a short shifter of eBay that comes straight up from the t56 box & ditch the VE shifter. They're not cheap.
Also in the picture it looked like someone's welded that driveshaft at home, which is useless.
Has the flywheel been measured correctly so the throw out bearing is just resting on the pressure plate? As that adaptor plate also looks very thin. Is it made of steel or aluminum?

If you need any help with details please ask.
This is what took Neil Griffith so much research was to get the right spacing with the adaptor vs flywheel & thrust bearing. The end of the spline should also perfectly fit into the flywheel with the spigot bearing on the end.
I also went through a lot to work this out, hopefully this part of your conversion is correct as that will make it worth the money & save you a lot of time.

So sorry to hear about the box.
If you decide to use the Tr6060 then google Tr6060 modified shifters. There's a YouTube clip of a guy that's made a good one for a BMW. Get that done & it will bolt straight up to the adaptor, bellhousing, clutch is all the same. Should be both 26 spline count & same length.
Mike Beck
Goo Roo
New Zealand
UZZ32 No.32 & JZZ31 3.0GT

Posts: 5824
Reg: 11-2005

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Thursday, January 08, 2015 - 09:30 am, by:  Mike Beck (Gold_40gt) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Impressive build Damon.

The results will be well worth it!
Damon Cornish
Tinkerer
Qld
V8

Posts: 95
Reg: 03-2009

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Thursday, January 08, 2015 - 03:12 pm, by:  Damon Cornish (Boz) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Thanks Clayton,
Yeah looks like the kits a bit of a dud. Might be ok for some but it's not going to cut the mustard for my build.
Just put both the boxes on a skid and sent them to Mal wood, he'll pull them apart and we'll go from there.
He seams to think that my power goal would be borderline for the older t56 anyway.
I'll probably end up with a magnum hybrid of some description. And it'll definitely have a different shifter.
I already have the jzz30 shifter trim surround and have ordered the bottom boot from ayamaya with the brake pedal.

The adaptor plate is made from 6061 but it's only 10mm thick.
I really brought the kit so I didn't have to think about it too much but looks like that's not going to be the case.

There wasn't a spigot bearing with the kit when it arrived but I've been in contact with the guy who built it originally and he said he ran one 15mm x40mm. I'll have to do some measuring now. How much float should there be between the crank and the input shaft?

Thanks Mike, I hope so. I'm sick of spending money on it. I just want to drive it. Ha ha
Paul Mainey
TryHard
NSW
Twin Turbo V8

Posts: 259
Reg: 06-2006

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Thursday, January 08, 2015 - 03:50 pm, by:  Paul Mainey (Gttv8) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

I think the spigot should be more in the vicinity of 15mm x 32mm.

That's what I use for my PPG T56 box.
Clayton Carlyle
TryHard
NSW
v8 soarer twin turbo

Posts: 355
Reg: 04-2009

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Thursday, January 08, 2015 - 04:52 pm, by:  Clayton Carlyle (Clayton) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Yeah Paul that sounds right from memory, I'm away with work for a week but can measure when I get home off the spare engine.
Castlemaine Rod shop do a good cnc'd alloy adaptor, it's very thick, & sell the spigot you need.
I think Paul & I have the same steel adaptor from Andy Losurdo, is that right Paul or did you get Neil's one?

The key to it fitting correctly depends on the thickness of the plate. You need to set it up behind the engine on the ground without the bellhousing & workout all the measurements. Remember the throw out bearing should just touch the pressure plate.
After studying that photo on the for sale ad, I should have warned you straight away but saw that it was sold so didn't bother. Any chance of getting your money back?
Paul Mainey
TryHard
NSW
Twin Turbo V8

Posts: 260
Reg: 06-2006

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Thursday, January 08, 2015 - 08:20 pm, by:  Paul Mainey (Gttv8) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Yeah Clayton we have the same adapter plate. I have one of Neil's old R154 plate too.

I can't remember off the top of my head but are the input shafts on the 6060 boxes shorter than the T56. If so the 10mm plate might be better suited to ensure proper engagement on the spigot.

The spigot bearing will be 15x32. It is easy to get one off the shelf at any bearing place in 9mm width(Part No. 6002-2RS) or you can order a wider 13mm (Part No. 6300-2RS I think). Either way your local bearing shop will have something to suit. They are nothing special.

There are some tutorials on setting up the hydraulic throwout bearings on the net telling you what measurements to take to determine if any spacer is required etc. Can point you in the right direction if you get stuck.

And by the way, love the build Damon.
Damon Cornish
Tinkerer
Qld
V8

Posts: 96
Reg: 03-2009

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Sunday, January 11, 2015 - 07:55 pm, by:  Damon Cornish (Boz) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Thanks guy's.
Turns out i actually had a 6002-2RS bearing in my toolbox, not sure why but that was a small win ha ha.
I've been looking at that CRS adapter, looks like the business but I'm going to wait till I hear back from Mal Wood regarding the gearbox before i make a decision on it.

gearbox damage photo's to follow

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Damon Cornish
Tinkerer
Qld
V8

Posts: 97
Reg: 03-2009

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Sunday, January 11, 2015 - 08:01 pm, by:  Damon Cornish (Boz) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Not a lot of room around master cylinder.
Interior looks like a bomb hit it but its not going back together until 1. the manual conversion is sorted and 2. I've worked out what to do with gauges.

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Damon Cornish
Tinkerer
Qld
V8

Posts: 98
Reg: 03-2009

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Sunday, January 11, 2015 - 08:07 pm, by:  Damon Cornish (Boz) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Holden V6 throttle body mods

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tried all sorts of things to get them clean and shiny looking (clr, carby cleaner, brasso, silvo and the mag polishing cotton wool, cant remember what its called.) bloody good thing they'll be almost completely hidden.
Damon Cornish
Tinkerer
Qld
V8

Posts: 99
Reg: 03-2009

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Sunday, January 11, 2015 - 08:13 pm, by:  Damon Cornish (Boz) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

the reason for the throttle body mods and also something that made my heart beat a bit quicker than normal...I think a picture is worth a thousand words in this case.

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Damon Cornish
Tinkerer
Qld
V8

Posts: 100
Reg: 03-2009

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Sunday, January 11, 2015 - 08:18 pm, by:  Damon Cornish (Boz) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)


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