Bay Window with 1.9 TDI engine -> READY

[jp]

Great write up thanks for sharing and really interesting to hear your thoughts about the flip box especially as this was gonna be my next step... so are you thinking I should re-gear my 2ltr bay box?

Mine has already had 4th done by Cogbox but it isn't really enough/ could do with a 5th to knock another 1k off the revs. I bought the box of RichBaker78 who had the gearing set up by Cogbox for his 1776 lawn mower engine so was never going to be perfect for my TD engine.

Cheers
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1971 Devon Bay with 1800 Ford Turbo Diesel Engine (wip)
1983 VW Golf GTI Campaign
1979 Mini 1275 GT
2013 Scirocco TDI GT

[richbaker78]

Interesting - looks like a nice trip.
I would have thought the TDi box was the perfect solution....I guess the Renoault UN1/Porsche 915 are all in the tooexpensive category?

can you not find a compromise by lowering the box and engine more and lowering (relatively raising) the suspension? I see you are running stock height.

What is the issue ? are they actually binding ?

[Wilfred]

The flipped box is a solution, but definitely not perfect.

Going low is a real compromise for me.

When I put the tdi with the box in the van, I was really going for high cruising speed. but the wind noise above 100 kph is just too much, so 100 - 110 is good enough.

therefor, a 4 speed gearbox could be enough, but with longer 4th or longer overall gears.

I am going to dig into this.

I am not disappointed. Just not as happy as I thought I would be.

I will keep you updated in my quest for the best gearbox solution for me.
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[splitbusvanatic]

The t3/t25 guys are running the flipped a4/Passat transmission with no hassles.
But they have a wider track of course.
Not much wider.
However It makes all the difference to Angle of cv stretch.

[Wilfred]

I Know. And again, I would like to stress that I do not have any specific issues that can not be solved. After all, I have driven to quite some kilometers already (to England, to Italy for example). And I am driving it at work at the moment, with a big smile. A colleague of mine was driving behind me. He has a Jeep with a v8 engine. I knew he was driving there, so I pushed the throttle a bit more than I usually do. At work he noted: 'that van does pull like a mofo. I had a hard time keeping up with you.'

So, its really not all bad

But it's just that it doesn't fit as well as I would like. There is always a compromise somewhere, either ride height, tire size, or CV angle in my case.
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[splitbusvanatic]

I am thinking about mating up reduction boxes to the flipped box.
Would that work I wonder. ?

[Wilfred]

been looking into that, but thought it would be too much work for now.

I am preparing for the holiday at the moment. one thing I did, was finally mount the engine right... the engine mount was not correct, resulting in a bit of an angle for the engine and gearbox. Therefore, 1 of the flanges for the axles on the gearbox was higher than the other. Finally took the time to fix this.

also, replaced the clutch. Smoked it up last year, trying to get on a very steep hill. Also found a little rock, wich probably toasted the clutch plate. Luckily no damage on the flywheel. REason to make a cover on the starter motor, there is quite a gap now, in which little rocks can easily enter the clutch area.

Oh, and i really wnat new shock absorbers, but i am in doubt cause of the money. I like the red koni type, but the are so expensive. anybody got advice?
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[Wilfred]

Well, working on the clutch at the moment. Noticed the pilot bearing in the crankshaft was shot. Had trouble getting it out, but with my homemade bearing pullerg it came out!



homemade tool:



with the bearing:



also replaced the sump gasket. had a feeling it was leaking.



Today, the new bolts for the flywheel will arrive, so tonight I will put it all together. with a new clutch and all. Hopefully drive tomorrow!
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[Wilfred]

So I did this. Replaces shock absorbers with the red Koni's. Best there is, so it seems.

also repalced torsion bars with those from a pick up. these are 3 mm thicker, so stiffer. Which is good with the heavy diesel engine in the back.


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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[splitbusvanatic]

Always good to login and see updates. Well done

[Kai]

Glad your still persevering with yours. I drove my van for the first time this year last week and must say it was lovely with the flipped box. Although 110KMH in mine would be smashing. My solution was to buy a BV43 turbo, some larger injectors and a bigger chargecooler pump, probably a larger charge cooler radiator will be on order too.
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Think......

Don't sleep and drive!!!

[Kai]

And....

As you don’t want to lower your van and are worried about the driveshaft angle. If somewhere you could convert to a larger diameter CV this would help. I know in the Porsche scene they use the larger 930 CV joints which give a test angle meaning the gearbox can be pushed forwards. No idea if this applies to your van. Arnt you using stock Bay driveshafts? Then this might be doable. The alternative is to lower your engine and gearbox. With the T25 they lower the engine and gearbox 30mm?? I know with mine if I want to remove the rear spring I have to undo the the drive shaft to allow the rear arm to drop enough to remove the spring. The drive shaft catches on the rear arm near the out CV joint.
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Think......

Don't sleep and drive!!!