My KAD 16v project...
Turbo Mini Forums

From your Curborough video heel and toeing on down shifts will make 2nd last a bit longer! My JKD 5spd used to last 1000 miles if i was lucky!

On 5th Sep, 2011 Vegard said:
I stand corrected. You should know

That was my first or second blast round of the day, just getting used to the car. I started to heel and toe in the afternoon. The synchro going was proberbly because or not helped by the fact the clutch was dragging.

Matt W

I know this isnt turbo but i find this forum loads better than others for getting opinions and feedback, so i hope people dont mind me posting here.

Stripped the box down, heres a pic of the knackered synchro ring, its butted up dead close with no gap.




Something thats bugging me is this amount of moment on the shaft. We might have made a fuck up and missed something out, surely it shouldnt move this much?

Matt W

Ive also found some aluminium flakes in the gearbox casing, not a clue where that has come from? maybe from the casting of the head? Any ideas? no sign of it coming from the gearbox

Has anyone drilled the box for an oil tempeature sensor? 1/8npt? if so where have you done it?

Edited by mw3 on 7th Jan, 2012.

Matt W

Not sure about the loose synchro hub, but if it is built around a standard main shaft, the first gear journal should hold the first/ second synchro hub from moving that much.

As for the aluminium flakes. If they are thin and smooth, take every bearing cap off the engine and check the bearings. When I had a center bearing failure the sump was full of smooth thin copper flakes that all came from the center bearing, but it was a severe failure, enough to let the pistons touch the head.

Oh and that bulk ring is totally worn. Check the condition of the cone on second gear too, that should have a nice even coating all th way round

Edited by Sprocket on 7th Jan, 2012.

I have started posting on Instagram also my name on there is turbomk1golf

Nothing is impossible it just costs more and takes longer.

Thanks for the help guys, ive now managed to get the pot joint off the diff output shaft, drilled and levered the cap out in the bottom of the pot joint supported the pot joint on two thick pieces of angle iron across bits of wood and wacked the end of the gearbox shaft with a brass drift and a fuck off hammer.

The wire circlip split into three and the output shaft cut chunks out of it. The output shaft looks unmarked.


Sprocket - second gear synchro cone looks fine, im thinking that with the KAD conversion it looks like the gearbox flange and block have been drilled to take bigger cap head screws, im wondering if the aluminium swarf might have come from this because the gearbox was fully built before this was done. Ill give them a ring on Monday.


Simon - Thanks for the picture i might put mine in the same place

Matt W

Can you get pictures of the swarf?

I seriously doubt it!

Are the threads in the sump plug OK?

Is the synchro ring cracked?

If something is worth doing, it's worth doing half of.

Right here is a picture of the swarf, i cleaned most of it out and didnt take a photo, these are a few bits ive just found in the box. The hack saw is to give you an idea of the scale. The synchro ring didnt crack, and the threads in the sump plug are spot on.

Matt W

I have spoke to KAD and they say that the swarf has come from them drilling the gearbox They tried to wash most of it out but there was obviously a bit trapped in the bottom. Nearly rebuilt the box back up now and i hope to have it on the rolling road at the end of the month. Should see a bit more power now everything has nicely bedded in.

Heres the mag cover.

Matt W

Nice! When is the mag out?

That looks stunning mate

I like the number plate, crap it definately isn't!

I'm surprised at kad leaving swarf, ESP for the price hat you pay... I suppose not everything is perfect.

I run a supercharger and I don't care the TB is on the wrong side.
VEMS + 12 PSI + Liquid Intercooler = Small Bore FUN!

To be Fair to KAD i was rushing them to get the engine ready for Mitp and they saved me a lot of hassle in not going down to kent.

Thanks for the comments guys, i was actually reading your feature whilst the photoshoot was going on Chris, lots of secrets kept hidden!

Matt W

Ive got the photos from the shoot now, really good stuff from Minimag. Im really impressed.

Matt W

Very nice,

needs the bonnet off to show the motor

rick

very nice well done looks smart as

Done now needs redoing lol

bang tidy

Just finished reading the magazine article and this thread pops up, very nice mini indeed.

Matt W

Wants an anodised rocker cover to match the wheels ??

On 18th Jan, 2012 mw3 said:

On 18th Jan, 2012 cossierick said:
Very nice,

needs the bonnet off to show the motor

rick

All photos are coutesy of Mini magazine