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 dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on March 17th, 2008 at 07:04 PM |
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"Valentino" and his MEGA! IRS Tranny
Well, Valentino is not his real name, to protect the innocent,
but he asked me to assemble this tranny to go into his streeter 'super'.
There are not many things inside this tranny that would want anything better.
"V" was very good and had all his parts nice and clean, and after some discussion we settled on the following ratios:
4.125 diff ratio, on a rare ZF swingaxle limited slip.
(yes, in an IRS!...more soon)
FTC 3.778 first,
FTC 2.357 second gear,
ALBINS 1.722 third gear,
and what appears to be an old Hollinger
1.333 straight cut 4th gear.
Did you say 1.33 for fourth?
Yep, thats over 4400rpm at 100km/h!!
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on March 17th, 2008 at 07:15 PM |
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My normal first step is to set up the crownwheel and pinion.
This particuar case was quite difficult this time, because the shim that VW used was miles wrong.
After much trial and error I was able to use a 0.15mm shim to get the pattern as close as I could,
and used .006" back lash as the factory minimum.
Normally the shim is around the 0.5 to 0.7mm with this particular tooth form.
But as it was the contact was right on the tip of the pinion.
VW probably set it this wat because it was within their spec for silent operation with about 50hp.
It WAS centred height wise, but with so little contact it would have failed with the power that Valentino has.
Each time the pinion shim is changed,
te backlash must be re-set to spec BEFORE checking the contact pattern with bearing blue.
It took me a whole day to get this one sorted.
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on March 17th, 2008 at 07:25 PM |
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The next step was to trial assemble the gear stacks and adjust the end clearance of each gear.
I have used the early metal caged bearings throughout:
I drilled holes through the hubs for 1 and 2, and also for 3rd and 4th.
This allows for better oiling of the gear faces under thrust loads.
Here is the first stack trial assembled on the pinion shaft.
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on March 17th, 2008 at 07:39 PM |
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Once the end clearances were set and the intermediate housing clearanced for the 1.333 fourth gear,
I scrounged up some missing reverse linkage parts in preparation for the setting of the forks in the jig.
Here you can see the pin that engages the ERCO reverse idler gear:
Steel forks were used for the gear selection, because some are made from a weaker bronze material.
Also the nose cone was machined flat in preparation for the steel thrust plate that helps to retain the main shaft bearing.
Valentino's car has a late model three-bolt nose cone mount,
which actually is the strongest nose cone there is, except less used because it came out on later L bugs.
| Quote: | Originally
posted by westi
That's mad Alan.
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56astro
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| posted on March 17th, 2008 at 07:43 PM |
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No Junk there!!!!
VW car, VW engine ...... keepin it "real"
35MPG on 101.3kPa |
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on March 17th, 2008 at 07:45 PM |
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Here is the gear set and intermediate housing installed in his case.
Valentino had a salubrious powder coated grey colour for the case, and then polished the ribs.
The nose cone will be done as well after it returns to Sydney.
The clutch fork has been fully welded,
and the long arm is used for less clutch pressure on the pedal.
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on March 17th, 2008 at 07:53 PM |
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Well, that last shot showed a peek of those massive side covers.
Them, and the special adapter stubs, are what allows the Swingaxle ZF to be used in an IRS tranny.
There is a support bearing inside the covers,
retained with a couple big circlips.
The taper on the tip is to enable the assembly into the swingaxle fulcrums, sight unseen.
A bit difficult, but it all went together well.
These ones take a Kombi CV joint, and are about 2" shaft size.
No snapping off these suckers.
Ahh! All done!
| Quote: | Originally
posted by westi
That's mad Alan.
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hellbugged
A.k.a.: Daimo Pell
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| posted on March 17th, 2008 at 08:30 PM |
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i guess someone has to ask, sooooooooooo with a user name like mine, here 'tis,
why the swinger ZF only to go irs?
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nbturbo
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| posted on March 17th, 2008 at 08:36 PM |
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Dave-my jeans are now officially "creamed"-nothing more to say.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on March 17th, 2008 at 08:53 PM |
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Apparently the swinger ZF inside is stronger,
plus no more broken splines at the CV flange.
Better support with the bigger bearing too.
| Quote: | Originally
posted by westi
That's mad Alan.
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hellbugged
A.k.a.: Daimo Pell
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| posted on March 17th, 2008 at 09:01 PM |
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ahh  , oh, and very noice as usual........
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 matberry
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| posted on March 17th, 2008 at 10:23 PM |
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You mean those output axles are UNBRAKO !!!
Fantastic Dave
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
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mactaylor
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| posted on March 18th, 2008 at 06:27 AM |
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valentino the muffler man?
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Turbo54
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| posted on March 18th, 2008 at 12:05 PM |
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19" wheels Valentino?
C'mon kids gather round,
there's a new sensation hitting town,
It's moving straight, low to the ground,
it'll pick you up when your feeling down.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on March 18th, 2008 at 03:41 PM |
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Muffler man?
No not 19" wheels.
| Quote: | Originally
posted by westi
That's mad Alan.
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VWCOOL
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| posted on March 18th, 2008 at 04:08 PM |
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Mmm, this is a tasty burger!
Pay your debts, CxxT
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on March 18th, 2008 at 04:54 PM |
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| Quote: | Originally
posted by dangerous
Apparently the swinger ZF inside is stronger,
plus no more broken splines at the CV flange.
Better support with the bigger bearing too.
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From memory Jeff had something very similar
in his green beetles all those years ago.
| Quote: | Originally
posted by westi
That's mad Alan.
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hellbugged
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| posted on March 18th, 2008 at 05:09 PM |
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| Quote: | Originally
posted by dangerous
| Quote: | Originally
posted by dangerous
Apparently the swinger ZF inside is stronger,
plus no more broken splines at the CV flange.
Better support with the bigger bearing too.
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From memory Jeff had something very similar
in his green beetles all those years ago.
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nah.......straight irs ZF with type1/kombi output shafts.(still there, but don't tempt me yet, i have to finish fixing the notch first )
i was telling him about this and your other recent builds (thrust plates etc) today........he likes all the theories, ideas/priciples behind them all
as well as the execution of what is learn't..........that's his sort of thing as you prolly know.
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matberry
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| posted on March 18th, 2008 at 05:16 PM |
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Jeff should send some of his junk up this way, for a holiday from all those wood shavings.
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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mactaylor
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| posted on March 19th, 2008 at 07:20 AM |
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BAKAHAG is that reversing a old woman? or taking a punt on one.
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humpty
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| posted on March 24th, 2008 at 09:52 PM |
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| Quote: | Originally
posted by matberry
Jeff should send some of his junk up this way, for a holiday from all those wood shavings.
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Bugger that.... Jeff should send some of that unused junk my way.... I'm one of the OG Hellbug customers from back in the day.... Hell, I even still
have one of the OG stickers on my car!
Thats dedication right there...
Anyway.... That is a very interesting way around the weak link.... But tell me this.... Why use the old ZF and not go with the new tech Quaife?
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westi
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what the
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| posted on March 25th, 2008 at 10:06 AM |
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why does this look like somthing i have seen before.
i think this might be parked in my shop.
i thought it might be some of your handy work involved but wasn't qiuet sure.
we had to make some bracing and other mods.
i will post up some pic's when i get back from fiji.
bula bula.
down sharon.
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mactaylor
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| posted on March 25th, 2008 at 06:38 PM |
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nisa bula westi! where are the side covers from cant find them anywhere?
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on March 25th, 2008 at 08:02 PM |
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| Quote: | Originally
posted by westi
why does this look like somthing i have seen before.
i think this might be parked in my shop.
i thought it might be some of your handy work involved but wasn't qiuet sure.
we had to make some bracing and other mods.
i will post up some pic's when i get back from fiji.
bula bula.
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I think that is Henry's handy work you speak of.
That tranny was once in Matt's drag car
and was part of Jeff's contribution to their mid 90's partnership.
Now making a home in another up and coming All Motor car from Sydney(I see all)
| Quote: | Originally
posted by westi
That's mad Alan.
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humpty
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| posted on March 25th, 2008 at 08:16 PM |
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| Quote: | Originally
posted by dangerous
| Quote: | Originally
posted by westi
why does this look like somthing i have seen before.
i think this might be parked in my shop.
i thought it might be some of your handy work involved but wasn't qiuet sure.
we had to make some bracing and other mods.
i will post up some pic's when i get back from fiji.
bula bula.
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I think that is Henry's handy work you speak of.
That tranny was once in Matt's drag car
and was part of Jeff's contribution to their mid 90's partnership.
Now making a home in another up and coming All Motor car from Sydney(I see all)
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In that case....
Oh great and wondrous Muffin Man, the see'r of all things good and fast, what praytell is in my future?
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hellbugged
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| posted on March 25th, 2008 at 08:17 PM |
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| Quote: | Originally
posted by dangerous
| Quote: | Originally
posted by westi
why does this look like somthing i have seen before.
i think this might be parked in my shop.
i thought it might be some of your handy work involved but wasn't qiuet sure.
we had to make some bracing and other mods.
i will post up some pic's when i get back from fiji.
bula bula.
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I think that is Henry's handy work you speak of.
That tranny was once in Matt's drag car
and was part of Jeff's contribution to their mid 90's partnership.
Now making a home in another up and coming All Motor car from Sydney(I see all)
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yeah Matt's had a similar looking side plate, also IRS of course................sold last spectacular swap meet, dirt cheap too
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matberry
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| posted on March 25th, 2008 at 08:23 PM |
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Ahhh the missing links.
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on March 25th, 2008 at 08:32 PM |
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| Quote: | Originally
posted by humpty
| Quote: | Originally
posted by dangerous
| Quote: | Originally
posted by westi
why does this look like somthing i have seen before.
i think this might be parked in my shop.
i thought it might be some of your handy work involved but wasn't qiuet sure.
we had to make some bracing and other mods.
i will post up some pic's when i get back from fiji.
bula bula.
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I think that is Henry's handy work you speak of.
That tranny was once in Matt's drag car
and was part of Jeff's contribution to their mid 90's partnership.
Now making a home in another up and coming All Motor car from Sydney(I see all)
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In that case....
Oh great and wondrous Muffin Man, the see'r of all things good and fast, what praytell is in my future?
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I see in your future a 12 second 1600, grass hopper.
(but I can see an 11 second one over here so hurry up!!)
| Quote: | Originally
posted by westi
That's mad Alan.
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westi
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what the
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| posted on March 26th, 2008 at 08:06 AM |
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nice one.bula bula.
i don't know dave i think that loverly grey would be a hard act to follow.and i have never seen side cover's like this before.even the polished high
side bit's on the rib's.the other tranny in the shop ,the one which i am yet to update photo's only because i am away that is in a drag car to
be,that box was biult by Mr HS 618.
anyhow i will be back next week.photogragh's tell now lies.
cya
P.S more fun=more sun.i have only heard this about 100 times,i thought i might pass it on.
down sharon.
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mactaylor
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| posted on March 26th, 2008 at 07:02 PM |
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im confused where are the SIDE PLATES from?
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