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.

























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