200Tdi into 109

[Ren Ching]

Hi All,

Some of you know that I started RedSq's (my 1960 109 SII LWB) engine swap over to a 200tdi this past weekend. Here is a link to a facebook album of photographs of the work so far. I think everyone should be able to see it.

http://tinyurl.com/3tmp9ab

Cheers
Dave

[headdamage]

Looks good... what are you going to do with the turbo?

[Ren Ching]

Hi Andrew. Was planning to move the turbo using a schedule 40 elbow and some flanges. I also bought a set of defender manifolds and turbo on ebay uk. Not really sure what I am going to do but will have a better idea once things start coming together.

[Antichrist]

Looks interesting, I'll be watching.
It might though if you were drinking more appropriate stuff.

[Firemanshort]

Nice work Dave - I thought you had all but given up on the Red Square with your cushy new 300 Tdi D-90.

[Ren Ching]

I'm too deep in the hole with that thing to give up on it :)

Nice work Dave - I thought you had all but given up on the Red Square with your cushy new 300 Tdi D-90.

[cgalpin]

LOL. Looking good man!

[junkyddog11]

Hey, nice job on the timing pin thingy.
I have been scalloping out the cross member and welding in a section of tube....similar to the modification for frnt driveshaft clearance on SOA conversion. Allows the use of standard tooling.
I might like your idea better.

[Ren Ching]

Thanks, yeah, I didn't want to do all that to the chassis. Especially since I have a habit of re-arranging those crossmembers...

Now I do still need to figure out how to make a useable drain plug. Hoping there is enough room to get the factory plug in and out.

Hey, nice job on the timing pin thingy.
I have been scalloping out the cross member and welding in a section of tube....similar to the modification for frnt driveshaft clearance on SOA conversion. Allows the use of standard tooling.
I might like your idea better.

[mikeslandrover]

Hi Andrew. Was planning to move the turbo using a schedule 40 elbow and some flanges. I also bought a set of defender manifolds and turbo on ebay uk. Not really sure what I am going to do but will have a better idea once things start coming together.

I think the defender manifolds will work with a lot less fuss, you were lucky to find them.

[junkyddog11]

I took a pile of steering conversion photos yesterday and now cant find the damn cord for the camera to get them loaded........and my card reader seems to be non functional.........hopefully shopgirl can get it sorted and up on the facebook.

[Ren Ching]

Thanks Matt, I'll look for 'em.

Mike, I have been surprised at how often the defender 200tdi stuff comes up on ebay uk.

[D90user]

Hey, nice job on the timing pin thingy.

I agree! But I have a 200tdi defender motor and that boss is still blank... if there is a notch in the flywheel what models had that hole (just curious??)

[Ren Ching]

there isn't a pre-existing notch. but there is a pair of hash marks. I'm pretty sure my 5 bearing 2.25 petrol had a plug in that location and have since seen a few photos of 200tdi's with one as well. You can really make the hole anywhere since you are drilling your own hole for the pin. I was a bit concerned about upsetting the balance of the flywheel but i decided that the amount of metal removed was so small and the amount of imbalance created would probably be no more than that caused by the clutch pressure plate being bolted on any which way. I could always drill another hole 180 degrees out, but that is just getting a bit beyond "Ren good"

I was a bit bummed that I got the thread pitch wrong. Anybody know what the proper thread is for these flywheel housing plugs?

I agree! But I have a 200tdi defender motor and that boss is still blank... if there is a notch in the flywheel what models had that hole (just curious??)

[kevkon]

Isn't it BSP?

[Ren Ching]

I tapped mine to 1/4" BSPP and I couldn't even get the original plug started in the hole. The 1/4" BSPP plug from McMaster Carr fit perfectly.

Could be metric or maybe 1/4 NPT. Dunno...

[oilburner]

Do you have a thread gauge?

[130Tdi]

so what the flywheel locking tool wont thread in ? Thats the only reason you went to this trouble right ?

[Ren Ching]

Somewhere...don't know if it has one for 19. Or the metric pitches. I've been pretty successful with figuring out threads by other means. On this one I just ass/u/me(d)

Do you have a thread gauge?

[130Tdi]

Do you have a thread gauge?

Was that a Canadian bitch slap ?

[Ren Ching]

the bushing/fitting that I used as a drill guide and the drill bit that made the hole are now the timing tool and have been tucked away in the kit with all the other timing tools. Which was always my "Plan B" all along so no real biggie.


so what the flywheel locking tool wont thread in ? Thats the only reason you went to this trouble right ?

[JBinAlabama]

Look'in Good!

[junkyddog11]

the bushing/fitting that I used as a drill guide and the drill bit that made the hole are now the timing tool and have been tucked away in the kit with all the other timing tools. Which was always my "Plan B" all along so no real biggie.

I'd prolly think about finding / making a regular steel pin 'cause if you snap a drill bit off in there you'll be bummin' and drill bits do snap pretty easily in that direction especially with the considerable force you'll get in that location with just a small slip at the other end.

[oilburner]

Was that a Canadian bitch slap ?

No way, just wanted to make sure he knew they existed. Dave's doing good.

Dave if you end up going power steering and you want a scout box I have 2 or 3 good ones.

[Ren Ching]

He he yeah I know they exist. Have no idea where they are though :(

Have a P38 box already courtesy of Crazy Ray's.

No way, just wanted to make sure he knew they existed. Dave's doing good.

Dave if you end up going power steering and you want a scout box I have 2 or 3 good ones.

[Ren Ching]

He he yeah I know they exist. Have no idea where they are though :(

Have a P38 box already courtesy of Crazy Ray's.

@ Matt, thanks for the tip about breaking the drill bit I should have thought of that. I'm going to order the correct size pin from mcmaster carr. let me know when you find the camera cable. In the meantime, got the proper mounts now so the engine is setting in place. I am concerned about the clearance at the front axle to crank pulley and have a few ideas about that. Pretty sure I have the crank pulley from my 5 brg. 2.25 so may try that. Also have toyed with trying something I have wanted to do for a long time, extending the spring hangers down an inch or two to mimic the placement of the MOD/1 ton suspension. Curious to see if anyone has done or tried to do that and what advice they have to offer. I wonder if parts exist for that. Guess I could hack my frame and just drop mine whatever distance I decide...hmmm...

[oilburner]

@ Matt, thanks for the tip about breaking the drill bit I should have thought of that. I'm going to order the correct size pin from mcmaster carr. let me know when you find the camera cable. In the meantime, got the proper mounts now so the engine is setting in place. I am concerned about the clearance at the front axle to crank pulley and have a few ideas about that. Pretty sure I have the crank pulley from my 5 brg. 2.25 so may try that. Also have toyed with trying something I have wanted to do for a long time, extending the spring hangers down an inch or two to mimic the placement of the MOD/1 ton suspension. Curious to see if anyone has done or tried to do that and what advice they have to offer. I wonder if parts exist for that. Guess I could hack my frame and just drop mine whatever distance I decide...hmmm...

I have a set of factory 1 ton spring hangers that I carefully removed from my old frame. If you remove your stock pieces carefully and they are not hacked and your frame is not a rusty POS I would do a straight swap. The XMOD hangers are a waste on my spring over. I am going to be welding them on in September so if you want to do this, it would have to be rather quickly.

[Ren Ching]

I'll send you some email

I have a set of factory 1 ton spring hangers that I carefully removed from my old frame. If you remove your stock pieces carefully and they are not hacked and your frame is not a rusty POS I would do a straight swap. The XMOD hangers are a waste on my spring over. I am going to be welding them on in September so if you want to do this, it would have to be rather quickly.

[Ren Ching]

Posted some updates on facebook. Have done a bit since august but did lose a few weeks to bad weather and a broken toe:


http://tinyurl.com/3tmp9ab

[Wolf Fabrication]

Have done a bit since august but did lose a few weeks to a broken toe

This thread is worthless without pics or at least a cool story.

[cgalpin]

Looking good Dave. But I thought this was a little more plug and play than this. Are there any specific factors contributing to the amount of fab work and other adjustments needed?

[Ren Ching]

Thanks Charles. The only plug and play part is that the chassis mounts are in the correct place. Everything else requires some kind of fettling to make it work. But, so far nothing extremely difficult. Notching the center crossmember was a bit nerve wracking to make the first cut.

Most of the complications result from it being a LHD truck and being a 109 which has a taller frame section than an 88.

@wolf, the broken toe was already addressed in the NOVA HH thread :)

Looking good Dave. But I thought this was a little more plug and play than this. Are there any specific factors contributing to the amount of fab work and other adjustments needed?

[Wolf Fabrication]

@wolf, the broken toe was already addressed in the NOVA HH thread :)Please. I don't read that thread anymore because all it is is Pedro claiming to show up and then not showing up, and Gustavo wanting to host a pool party at his house.:)

Oh crap, just found your toe! Nice one. In honor of your toe, I shall make it my avatar.

[Ren Ching]

LOL.

Way to keep the thread on toe-pic



Please. I don't read that thread anymore because all it is is Pedro claiming to show up and then not showing up, and Gustavo wanting to host a pool party at his house.:)

Oh crap, just found your toe! Nice one. In honor of your toe, I shall make it my avatar.

[Wolf Fabrication]

In honor of your toe, I shall make it my avatar. Okay, that was gross and only lasted a few hours.

Back on toe-pic.

[Ren Ching]

Yeah, that was not a very good idea. Even I was grossed out and it was my toe. Thanks for ruining my thread.

Okay, that was gross and only lasted a few hours.

Back on toe-pic.

[Wolf Fabrication]

I didn't ruin it, I just spiced it up a bit. It was boring anyway. Now get back to work and post more updates.

[rijosho]

This thread was just good before. Now it's Toe-riffic!

[mikeslandrover]

So what's new?:confused

[130Tdi]

Spoke with Ren this afternoon. He's just ordered the specialty exhaust parst from Steven Parker in the UK.