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Old 10-23-2018, 09:48 PM   #601
Atom D&D
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Got the pan welded back together and added some -6 AN fittings onto an OE rail.



I built a table to section the bellhousings. I’ll take some pics tomorrow. It’s supremely overkill, but I made it out of leftover junk from the shop.
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Old 10-25-2018, 11:12 AM   #602
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Ok, so here’s the table for cutting. I used two thick a$$ plates of aluminum with a lazy Susan bearing between them, put it on some slides with a chunk of allthread (I know it technically should be acme thread, but I’m using scraps) with some nuts welded to the end for adjusting. I welded some C channel uprights and made a fixture to bolt to my angle grinder using the spots where the handles go. That bracket isn’t really square, so my plan was to c-clamp it in place and adjust until I got it to the desired height and level with the table then drill for bolts to “pin” it at that height. Seemed to work alright.



Then on to the cutting. I started by just making a “contact” ring most of the way around so I could be sure that as I cut deeper I could verify the disk wasn’t deflecting or diving. Then I cut through in most spots, leaving a few areas NOT cut all the way through so it wouldn’t pinch the wheel. Then I laid the trans on its side and finished off the last bits.

The rings line up pretty good. I’m going to make a few mounts so I can stand my block on it’s nose, bolt the 960 bellhousing ring in place then put the trans section on and start welding. I plan on putting “straps” of aluminum across the weld to help tie everything together. We’ll see.

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Old 10-25-2018, 11:25 AM   #603
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That's wild. Safe to say most of us wouldn't know where to start on modifying a trans like that. Why change the fittings on the fuel rail ? Were they not compatible with BMW hoses ?
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Old 10-25-2018, 11:30 AM   #604
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That's wild. Safe to say most of us wouldn't know where to start on modifying a trans like that. Why change the fittings on the fuel rail ? Were they not compatible with BMW hoses ?
No. BMW are all raw hose, and also use a return system while Volvo is returnless. This way I can add a decent regulator and adapt whatever I need pretty easily.
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Old 10-25-2018, 12:59 PM   #605
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Originally Posted by Atom D&D View Post
Ok, so here’s the table for cutting. I used two thick a$$ plates of aluminum with a lazy Susan bearing between them, put it on some slides with a chunk of allthread (I know it technically should be acme thread, but I’m using scraps) with some nuts welded to the end for adjusting. I welded some C channel uprights and made a fixture to bolt to my angle grinder using the spots where the handles go. That bracket isn’t really square, so my plan was to c-clamp it in place and adjust until I got it to the desired height and level with the table then drill for bolts to “pin” it at that height. Seemed to work alright.
...
Inspired by Deboss Garage's audi trans build?

Very nice work!!

Last edited by Hank Scorpio; 10-25-2018 at 02:29 PM..
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Old 10-25-2018, 02:15 PM   #606
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Inspired by Deboss Garage's audi trans build?

Very nice work!!
I saw this thread. Following his lead. Just making small changes.

https://www.bimmerforums.com/forum/s...d-to-fit-a-M73
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Old 10-25-2018, 08:24 PM   #607
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So, while sticking the two together, I was a little worried about alignment knowing that the trans input shaft has a bit of slop. I took two precautions. I made a sleeve of thin aluminum that I put around the splined portion of the input shaft and slid it into the throw out guide sleeve and I made basically an extra thick pilot bearing sized block of aluminum hoping that having more engagement on the output shaft would help align things. Then I put everything together and started with some sturdy tacks, then longer welds, then all the way around (where they meet at the moment) and lastly added the “straps”. I’m going to let that sit over the weekend and weld the inside next week. Then before I assemble anything for good, I’m going to take a scrap plate of aluminum and make a fixture so if I need to duplicate this down the road, I don’t need a spare engine laying around.



I’m also going to make some filler plates to cover the gaps between the two.
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Old 10-26-2018, 02:39 AM   #608
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You didn't happen to video the tool cutting did you? Be cool to watch that.
Nice work!
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Old 10-26-2018, 05:13 AM   #609
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I always read the title of this thread as "Atom's *Amazing* Wagon Project Update Thread".

You do great work.
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Old 10-26-2018, 08:50 AM   #610
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I love all the updates on this thread, but I read with hesitation as I want to attempt bits and pieces of what you do. I just know that it will end up in the alley and crushed.
Awesome stuff!
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Old 10-26-2018, 03:45 PM   #611
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Quote:
Originally Posted by vwbusman66 View Post
Inspired by Deboss Garage's audi trans build?

Very nice work!!
So, I looked up Deboss Garage and now my day off has been wasted. I can’t turn off his channel. He’s a smart guy with some serious skills.

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You didn't happen to video the tool cutting did you? Be cool to watch that.
Nice work!
I didn’t. I did the cutting early before work and there’s no one around to hold the camera phone. I did post a spinning video on the Facebook page, but not while cutting.

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I always read the title of this thread as "Atom's *Amazing* Wagon Project Update Thread".

You do great work.
Pretty much every time I see someone’s post that says has Amazon in it I see that too.

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I love all the updates on this thread, but I read with hesitation as I want to attempt bits and pieces of what you do. I just know that it will end up in the alley and crushed.
Awesome stuff!
Oh, I’ve made plenty of mistakes and scrapped some stuff. I just don’t show anyone that stuff.
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Old 10-26-2018, 04:53 PM   #612
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Castings look pretty thick - did you bevel before welding?
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Old 10-26-2018, 05:22 PM   #613
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Castings look pretty thick - did you bevel before welding?
I did on a percentage of it. I was concerned about beveling the whole thing and then the bevels not aligning and therefore the two not mating perfectly flat. So, I beveled, then left flats. My plan is to dig into the junction from the inside before I weld that as well. I can say that I welded it pretty hot, it was pulling stuff out from deep in the metal. When I make the fill plates for the remaining openings I’m gonna add ribs too. I’m confident in it.

Edit: if you look at the seventh and eighth pic (the first two with the trans sitting on the engine) in my last post you can see the bevels between the ribs where the blue squares are. It’s beveled all the way to the inner side of the housings.
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Old 10-26-2018, 06:45 PM   #614
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Never doubted your thoroughness - just wanted more detail on approach. As usual - nice work.
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Old 10-30-2018, 10:36 PM   #615
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Couple of pics with the pan on too.



Once I’m for sure done welding stuff up, I’ll make the trans and pan match the engine.

I’m pretty sure I can get by with the rear sump pan if I make a few modifications to the front crossmember and flop sides on the sway bar.

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Old 11-02-2018, 10:42 AM   #616
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PCV spacer/Oil filter blockoff/Motor mount plate (future)/Alternator adapter (future). Only got one side done. The second side should be much easier since there’s no PCV in the way.



Stoked to test fit things this weekend. Not stoked to do it in the rain (as usual).

Modified crossmember (still need to add some bracing, but want to check fitment first.

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Old 11-02-2018, 10:44 AM   #617
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Crossmember braced up a bit.


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Old 11-02-2018, 04:48 PM   #618
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Love the updates and progress. Fun one to follow.
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Old 11-03-2018, 01:12 PM   #619
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Tent city set up. Got fixturing to do before I can even start playing.
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Old 11-03-2018, 03:25 PM   #620
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Well, sits a little tight to the firewall. The trans mount and driveshaft are adjustable though, so I’ll probably slide it forward just a hair. The good news is the modified crossmember clears the 960 pan without having to cut into the sump any more. Sway bar might be tough. I made a fixture to locate where it ends in stock configuration, so I’ll flip it and see where it lands on the front of the pan.

Anywho...



Plenty of room to the core support



Overall height comparison (without the top half of the Volvo intake



Maybe it’ll transfer some weight back??
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Old 11-03-2018, 05:28 PM   #621
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On weight redistribution - Bimmer block cast iron or aluminum?

Saw this one today at our local C&C --



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Old 11-03-2018, 06:21 PM   #622
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On weight redistribution - Bimmer block cast iron or aluminum?

Saw this one today at our local C&C --



That would be TB member slick70's
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Old 11-03-2018, 07:52 PM   #623
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Quote:
Originally Posted by M.H. Yount View Post
On weight redistribution - Bimmer block cast iron or aluminum?

Saw this one today at our local C&C --
As far as I know cast iron.
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Old 11-03-2018, 07:52 PM   #624
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Once I was sure the pan would clear, I made some pieces to bolt to the pan rail then braced them multiple times to the crossmember. This way I can pull both out and build mounts out of the car.



Then I figured out turbo placement and made a bracket so I can build parts out of the car there too. Going to weld a 90° on the outlet for right radius.

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Old 11-04-2018, 05:15 PM   #625
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Last fixture for the weekend. This will make it so I can build the upper plenum at work and be sure it’ll clear parts in the car.



The crossmember with the pan rail fixture

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