My Tuned AE86 project

[thanhngo]

Update on Worm Drive for Speedo:

S14 worm drive is too small ID so wasted some money there.

Now I will try my luck with a J160 (IS200 AZ6) worm drive as its the only AZ6 I know of that runs a worm drive near the output shaft. Will see in about 2 weeks - but it looks like I may need to get a spacer machined & welded to my output shaft as a last resort.

Mating the AZ6 to the 4A block.
For individual reasons, I will probably try get this one to fit myself. Here are some of the key measurements I took;

(T50 vs Az6)
Face-shaft tip: 5.5mm vs 17.8mm
tip-spline start: 23.7mm vs 33.4.mm

Basically the AZ6 box runs a pilot bearing on the flywheel as opposed to the crank like the T50. Thus it has a much longer tip and sits much deeper inside the face of the bellhousing.

From the spline back, the T50 and Az6 are very similiar in lengths etc. The thrust release bearing from fit on each others shafts

Option 1. Adapter mating plate
There is a -22mm difference that needs to compensated for to get the clutch system to work like the T50. If you add an adapter plate to this, it would be at least -30+. So to achieve this with a Adapter plate, I would have to mill the bellhousing face down, use flywheel spacer, possible new bolt flanges. I figured this is a the more messy option.

Option 2. Cut and mate/weld both bellhousings. As crude as it sounds, this seems to be the most logical as I will need to spend time making sure I cut/weld at the most ideal points. So this is the option I will pursue.

Its a writeup of someone doing something simliar using a I200 6speed (az6 - J160).

I found this link:
http://www.rsmotorsport.com.au/forums/vi...57208cc182

Really helped and gave me some ideas.

...lots of babble but this needs to be carefully planned as I probably only have 1 shot at this.

Got a new a pilot bearing (15 IDx28 OD x7 WID). The Input shaft will need to be shaved at the tip, 1mm and shortened 9.7mm to work like a T50 would.

Next step is to locate cutting/matting positions.