139 replies to this topic

[moomin]

So what happens when either the clutch goes or an oil seal splits?

[Christian]

 moomin, on 11 June 2010 - 05:52 PM, said:

So what happens when either the clutch goes or an oil seal splits?

Not a problem as I'm planning on making a few once i've found a cheaper source of clutches.

[moomin]

I reckon make up a conversion kit and flog them for mega bucks

[Ecosse]

Got any idea's of how your gonna get the custom clutches cheaper?

[Whiteblock]

Surely now that the hub conversion parts are made any future clutch replacement would simply be a matter of grinding off the peened-over spacer/ pin ends, stripping out a new Toyota clutch disc friction surface, and reassembling and re-rivetting back together with new rivet pins?

No real need to make a new hub assembly, but might be worth having three new hub spacer pins on hand ready?

....thats assuming the new arrangement proves to be satisfactory of course...

[Christian]

 Whiteblock, on 16 June 2010 - 05:46 AM, said:

Surely now that the hub conversion parts are made any future clutch replacement would simply be a matter of grinding off the peened-over spacer/ pin ends, stripping out a new Toyota clutch disc friction surface, and reassembling and re-rivetting back together with new rivet pins?

No real need to make a new hub assembly, but might be worth having three new hub spacer pins on hand ready?

....thats assuming the new arrangement proves to be satisfactory of course...

That's a good point actually that I hadn't really thought about, although I might try and make up one other completely spare just in case I ever need one in a hurry.

[Whiteblock]

I know what you mean. It would be handy to have a spare at the ready just in case you need one in a hurry.

Might be worth trying out and evaluating the 'prototype' first though?

[Christian]

Yes not a bad idea. It should be fine, the Aygo clutch is quite 'meaty' for a 998cc engine.

Hopefully i'll be able to get cracking on with this project now as I've finally moved into my new house and literally just finished transporting the car over.

[Christian]

Big picture update

Aygo/C1/107 engine vs. Imp engine:































Test fitted into one of Jonathan's spare Imps:









Not a lot of room for throttle bodies!



A big thanks to Jonathan at Station Motorsports.

[Christian]

Some of the welding and plating already completed:







Lots more to follow.

[Christian]

More welding:



























Jonathan is a genius!

[The Avenger]

always loved the imp and hats off to you for thinking so outside the box with the conversion/engineering top job!

[moomin]

Impressive! Take out a mortgage to pay for the work?

[moomin]

Also engine be okay oil pressure wise with it sat at that acute angle? Won't it just pool at one side of the sump?

[Whiteblock]

 moomin, on 10 August 2010 - 07:07 PM, said:

Also engine be okay oil pressure wise with it sat at that acute angle? Won't it just pool at one side of the sump?

Modifications to the steel sump pan and the oil pick up to the pump are a given and should be relatively straightforward.

I'd also want to check out things like the camshaft lobe oil supply at that angle.... if the cams usually run in their own little oil 'baths' on these engines this might not work out anymore with the unit canted further over?

The transaxle/ bellhousing mods look well. The mating faces might well have distorted a little with the cutting and heat, and need a minimum truing cut, but modern sealers are a godsend for things like that.

Progressing nicely.

[Christian]

 moomin, on 15 July 2010 - 07:44 PM, said:

Impressive! Take out a mortgage to pay for the work?

No, no definitely not, but I doubt Jonathan will be taking on something like this again for awhile! It's turned out quite a lot more work than either of us anticipated!

[Christian]

 Whiteblock, on 11 August 2010 - 07:05 AM, said:

Modifications to the steel sump pan and the oil pick up to the pump are a given and should be relatively straightforward.

I'd also want to check out things like the camshaft lobe oil supply at that angle.... if the cams usually run in their own little oil 'baths' on these engines this might not work out anymore with the unit canted further over?

The transaxle/ bellhousing mods look well. The mating faces might well have distorted a little with the cutting and heat, and need a minimum truing cut, but modern sealers are a godsend for things like that.

Progressing nicely.

There's always going to be a risk by leaning the engine over as much as we've had to, but luckily these engines are cheap and plentiful at the moment. If it does throw it's toys out the pram we'll just have to revise the design slightly.

[Christian]

Today I began cutting out rot from my passenger side sill, to try and determine how much of it would need to be replaced. Thankfully I think I'm in luck. It seems that both the outer and inner sills are solid, the outer just covered in a little surface rust, and only the two sill extension pieces need replacing.

It's great news because with some proper repair panels I should be able to do the work myself.











I better blow the dust off the welder...

[Christian]

Sorry not much progress at the moment as I'm trying to launch a business and the Imp's had to be put on the back-burner for the time being. Here's a picture of the finished bellhousing though:

[Retro Richard]

Thats nice work, would it be worth taking moulds from it - if the conversion works well you could have a few bell housings cast and sell them on (as well as having a couple spare) to offset the original costs.