Friday, October 30, 2009

1ZZ FE engine to J160 gearbox adapter

I've spent a busy few weeks fabricating the adapter between the engine and gearbox.
I started off with a 16mm 400x400mm alloy plate as well a 4mm 400x400 transparent polycarbonate template and milled out the 76mm centres to locate the crankshaft accurately as the reference.
I carefully drilled out each hole for the engine and gearbox bolts and dowells on the clear template and them transposed them on the alloy plate.
I had a pair of helicoils tapped/fitted in the plate for the starter motor bolts as I made provision for the starter to be bolted to the plate rather than the plate to the starter - this will allow future removal of the starter without having to remove the egine/gearbox and seperating the engine/gearbox just to be able to access the OEM bolts.
A lot of counter sinking holes and tracking down suitable bolts/nuts to hold the combination together.
After everything was test fitted, the plate was trimmed down and linished to the adapter ring as pictured.

























Sunday, October 11, 2009

Engine mounts and start on pedal and seat position

Engine and bellhousing positions have been roughly set - would have been nice for the engine to sit a little further back and a little lower but this seems to be the best compromise for footwell packaging and sump longevity.

Note the ~12 degree lean of the 1ZZ as a result of the OEM sump/pickup design.

The 1ZZ has no provision for engine mounts when used in a north south position, so after much consideration I settled on the design below which attempts to spread the load over a number of different bolt mounting bosses on different planes.


I also made a start on fixing the seat mount position relative to the pedal position.

Seats are Whitepointer ADR compliant seats covered in marine grade vinyl running on MX5 rails.

Pedal box is a modified Arrow assembly.