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Gearbox Grind Out... Help!!

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adlbeetle66 Under the car.........again!

1,476 posts · joined Aug 2014 ·

#998445
Just need some guidance and help on how to grind out my gearbox!!
I'm putting a later model 1776 engine in my 1966 Beetle (standard - 1300).
I need as much help as i can get!!
I don't want to grind too far!!
Plenty of people have done it...
Cheers

hellbugged 48's and straight cuts

5,080 posts · joined Apr 2003 ·

#998457
Just put the engine in and turn it over by hand at the pulley with a bar and socket as you tighten up the four bolts gradually. (Keep it square to the box)

The teeth on the flywheel will cut it easy.

Once the bolts have gone tight, remove engine and grind a little more off for clearance.

Don't be scared, it's fairly simple

Some pics here....

http://forums.aussieveedubbers.com/viewtopic.php?tid=38560&page=10

adlbeetle66 Under the car.........again!

1,476 posts · joined Aug 2014 ·

#998463
I've been told thats a dodgy way of doing it, but if you have done it?

hellbugged 48's and straight cuts

5,080 posts · joined Apr 2003 ·

#998474
It's the most accurate cause it's cut with what's going in there.

It actually cuts it with a very nice finish

Yep done it too many times

adlbeetle66 Under the car.........again!

1,476 posts · joined Aug 2014 ·

#998476
Ok. Thanks for the help.
I'll probably post pics when done...

hellbugged 48's and straight cuts

5,080 posts · joined Apr 2003 ·

#998479
Yeah post pics, always nice to hear the end results...forum needs more of that

be easiest to turn over if you took the spark plugs out

Just take care near the starter bush. You will need to source an "adapter" bush to run a 12 volt starter in there too

Check your pressure plate is correct for the early thrust bearing as well

Change the input shaft seal if it needs doing while the engine is out too

adlbeetle66 Under the car.........again!

1,476 posts · joined Aug 2014 ·

#998480
Done the bush. The starter motor is in. The problem now is what to do with the 6V cold start relay...
Do you care if i post pics of the inside of my gearbox, and the pressure plate and get you to see if it will match??
You obviously have the experience...!!!
Cheers

coletrickle Wolfsburg Wizard

661 posts · joined Apr 2009 ·

#998482
or you can use a factory vw 180mm 12v flywheel,,You may need to look at getting a custom 180mm pressure plate if you plan on making decent power.I've got quite a few if you want to go that route and can't find one local,cheers

hellbugged 48's and straight cuts

5,080 posts · joined Apr 2003 ·

#998483
Ha hah was wondering if you still had them in stock col

pics are great!

adlbeetle66 Under the car.........again!

1,476 posts · joined Aug 2014 ·

#998484
Col, is it the flywheels or pressure plates you have?

coletrickle Wolfsburg Wizard

661 posts · joined Apr 2009 ·

#998495
adlbeetle66 wrote:The flywheels or the pressure plates?
flywheels,they came on the 71?and later 1300std bugs,what yours had orinally,and use a1200/40horse pp and disc but depending on the box you may need to fit a running ring to the pp if its a lage box/throwout bearing.

adlbeetle66 Under the car.........again!

1,476 posts · joined Aug 2014 ·

#998497
But is that gonna suit my 12 v starter?
Because i have a 6 volt engine that i took out, but i cant use that flywheel because ive now converted to 12v, and the teeth spacing is different...

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vlad01 Compulsive Aussie Vee Dubber

4,270 posts · joined Jun 2010 ·

#998759
hellbugged wrote:It's the most accurate cause it's cut with what's going in there.

It actually cuts it with a very nice finish

Yep done it too many times
Thats how i did it with no internet or any vw resources back in the day. Worked a treat!

71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE

adlbeetle66 Under the car.........again!

1,476 posts · joined Aug 2014 ·

#998919
hellbugged wrote:Just put the engine in and turn it over by hand at the pulley with a bar and socket as you tighten up the four bolts gradually. (Keep it square to the box)

The teeth on the flywheel will cut it easy.

Once the bolts have gone tight, remove engine and grind a little more off for clearance.

Don't be scared, it's fairly simple

Some pics here....

http://forums.aussieveedubbers.com/viewtopic.php?tid=38560&page=10

What do you grind it out further with?
Anything else you have to be aware of?
(shaft, T O bearing)

Joel Now containing 100\% E-Wang

9,368 posts · joined Feb 2006 ·

#998928
the 70s 1300 flywheels with 180mm clutch just use regular 12 volt ring gear.

How come you're sticking with the 1200/1300 gearbox?
that is going to be awful on the highway with a 1776 and doing those sort of revs you if you have your original non vented decklid you are going to get heat issues, (stand offs or holes behind the number plate fix that)

If you have a hard start relay you can just swap it out for a 12 volt relay, any 30-40amp relay will do the job.

hellbugged 48's and straight cuts

5,080 posts · joined Apr 2003 ·

#998929
Carbide burr or emery flapper wheel

Check your engine mounts too, change them if need be.

I think what col has would be an oring centre flywheel (so suit your later crank) with 180mm clutch but 6volt ring gear.

Anyhow, you've hot the hang of posting pics, so add them to here or your members ridè thread as you go

adlbeetle66 Under the car.........again!

1,476 posts · joined Aug 2014 ·

#998936
Here is my flywheel...

I have a 12 v starter, and my whole car is now 12 v.

2 attachments · Log in to view

hellbugged 48's and straight cuts

5,080 posts · joined Apr 2003 ·

#998955
Cool
Any pics of the pressure plate you are going to use?

hellbugged 48's and straight cuts

5,080 posts · joined Apr 2003 ·

#998961
Yeah ok

That's incorrect for your current thrust bearing. 🙁

You will need a center ring added to that pressure plate

matberry Moderator Go hard or go home

8,114 posts · joined Mar 2006 ·

#998972
And you need to check the crank and flywheel are compatible, you may have a 6 volt crank that will require a machining mod to the crank.
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE

adlbeetle66 Under the car.........again!

1,476 posts · joined Aug 2014 ·

#999006
hellbugged wrote:Yeah ok

That's incorrect for your current thrust bearing. 🙁

You will need a center ring added to that pressure plate
Thanks for that. Can you PM me or upload a pic of an example that i need to follow please?

1303Steve Scirocco Rare

8,650 posts · joined Aug 2002 ·

#999009
Hi

Be careful with filings they can catch fire easily and they are magnesium so water wont put them out.

I fitted a 228 flywheel in to my late single side plate box years ago, it just nipped up when the motor was fully tightened after I thought I had done enough clearing, so I backed of the motor bolts and then started the motor and did the bolts up a bit at a time, rough but it worked.Steve

adlbeetle66 Under the car.........again!

1,476 posts · joined Aug 2014 ·

#999131
Thanx. Will take a look later on.