newest project (Page 303/312)
Fiero2m8 NOV 14, 08:44 PM

quote
Originally posted by iNVisionPROTOTYPES:

Lookin' good!

Would be great to see the car in person sometime.




Hey Nick,

Yes I have a habit of taking it apart
I can bring it by your Dad's place when you're down visiting sometime.

Cheers,
Ryan

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Indy Northstar-Stretch

Fiero2m8 NOV 14, 10:10 PM
Adapter plate removed from the old flywheel.
Notice the burn marks from the kevlar clutch:


After machining work the adapter bolts with threadlocker to the new larger flywheel:


8 bolt pattern bolts to the Northstar crank and the 5 bolt Porsche pattern is not used:


Before and after clutch, pressure plate and flywheels:


1800 pound yellow pressure plate mounted inside flywheel ring gear, while the larger 2200 pound blue one mounts on the surface of the flywheel:


Pressue plate surface much larger contact patch:


Torqued new flywheel to 45ft/lb with threadlocker:


9" clutch replaces 8" one (actually they are metric sizes, but you get the idea):


Then the pressure plate bolts on with clutch alignment tool:
Fiero2m8 NOV 14, 10:31 PM
My son Andrew gave me a hand swapping the transaxle to the rebuilt one.
We started by transferring the accessories like the shift rod linkage clutch arm, throwout bearing and slave cylinder mount.
Then it was time to swap the 914 stub axle flanges to the larger 912 units:









Then we bolted in the transaxle:











Next steps are hooking everything up then axles with new CV joints and boots can be reinstalled...
Fiero2m8 NOV 14, 10:34 PM

[This message has been edited by Fiero2m8 (edited 11-14-2013).]

RCR NOV 15, 06:54 AM
Looks real good, Ryan.

Bob
bubbajoexxx NOV 15, 02:02 PM
Ryan your new stub axles are 911 not 912 as 912 are the same as the 914's
Fiero2m8 NOV 20, 12:18 AM
Thanks Joe for the correction, since you found them on eBay for me, you would know.
Not only did Bubbajoe sell the newest project at a reasonable price, he continues to provide tech support 5 years later

Tonight I installed the starter and when the engine wouldn't crank, I knew there was trouble...


First I checked the alignment but that wasn't the problem as it engaged fine but couldn't turn the flywheel.


Then I was concerned that the larger flywheel might be contacting the transaxle bell housing, but upon removal flywheel still didn't turn.


Next removed pressure plate and clutch.
Despite being back to square one, I did find the problem.


For some reason 4 of the 8 crankshaft bolt holes are countersunk deeper than the others making those 4 bottom out at torque spec preventing the flywheel from turning!






The machining wasn't consistent and here I've marked them L=Low and H=High.



Now I have to choose a solution to resolve this from a few options, keeping in mind neutral balance is what is needed.
Not impressed as the machining wasn't cheap!
Will NOV 20, 08:59 AM
Shorter bolts all around.

I have one on the shelf that I can measure this weekend.... I forget how thick the Northstar crank flange is. There's about a 10mm gap between the flange and the #5 main bulkhead. You can shorten the bolts 5mm and not lose any thread engagement OR shorten them 10mm and still not lose any strength as the flange is much thicker than the diameter of the bolts.

However, you've bottomed some bolts out on the rear main bulkhead. I've done this myself, so I speak from experience. The noses of the bolts have left imprints on the bulkhead and may have affected bearing bore roundness or alignment.
fieroguru NOV 20, 02:19 PM

quote
Originally posted by Fiero2m8:


Now I have to choose a solution to resolve this from a few options, keeping in mind neutral balance is what is needed.
Not impressed as the machining wasn't cheap!



Can't you just add a lock washer to the bolts in the low holes to bring the heads up closer to the others or just shorten the bolts? You could have some press fit spacer sleeves added to the short holes as well... There are several options that don't require a new flywheel.
Will NOV 20, 02:38 PM

quote
Originally posted by Fiero2m8:

Next removed pressure plate and clutch.
Despite being back to square one, I did find the problem.


For some reason 4 of the 8 crankshaft bolt holes are countersunk deeper than the others making those 4 bottom out at torque spec preventing the flywheel from turning!







A) Why does it look like the holes in the flywheel are threaded?

B) The threads on that bolt look severely galled... Are the threads in the crank ok?

C) Those look like metal chips on that bolt... Is that correct and where did they come from?