Ok, here is what my "welding transaxle case" thread was leading to. After trying to get info on the available audi adapters and clutches and not receiving any reply (turns out due to email problems beyond anyones control) i got a goofy idea in my head, so here is what I am in the process of doing.
I took a ford bellhousing for an older mustang (has linkage operated pivot, not cable but I am sure both would work) I milled off the tranny side so that there was exactly 3" left which is just enough to fit the clutch and starter, you could do maybe a 1/4" less or more but there was the space where the release fork sat and it seemed to put the audi release bearing in the right spot so ..... I then bolted it to the back of the motor with the ford flywheel and clutch installed and measured (hopefully right) where the input shaft would be centerd on the clutch, this is what i came up with, i forget, now i need to remeasure, but if i remember right i took 3" minus 11 mm off the end of the audi tranny then milled the supporting ribs only down an extra 1/2", then layed down a 16" peice of 1/2 6061 aluminum (lots of waste) and traced out the shape of the tranny, cut it out with a jig saw so that the tranny slips right in to the plate and is flush with the other side of it. That is as far as i have gotten due to newborn son and slotcar racing (scalex gt40) have taken up some time. The next step is to clean the case really good, i have been using muratic acid, seems to work but i dont have the guts to leave it on more than a minute, and 3m scotchbrite type wheels on an airdrill, then clamp audi and plate to a 1" thick peice of steel and have it welded, when it is done i will set it up in the mill and true up the plate. When i get my lathe working i will set up a peice of solid bar and cut it to fit tight where the pilot bearing goes and into the tranny where the input bearing would be, build a jig the right height to support the plate even with the ford bellhousing, bolt it all to the motor and clamp it and have that welded. Finally i will set it back up in the mill and true the bellhousing mounting surface. I have no idea if it will work but part of the fun is the journey, the plate cost $100 cdn and so was the tranny (thats free in usd) so i wont loose too bad i guess.
the only thing i wish i did was to not cut down the lower "t" shape brace at all untill i had it fitted because the way it all lines up the bottom of the audi bellousing (above the brace)lines up almost perfectly with the bottom of the ford bellhousing so you could leave that brace long and weld it right to the ford bellhousing without the plate in between at that point. I have pics but nowhere to host them so if you want email me and i will send them to you. When i am done i will confirm measurements.
ps. i havent figured out the clutch yet but i do have another goofy idea, which i will share if someone guesses or it works, whichever comes first.
[email protected]
[ February 26, 2003: Message edited by: Eric ]
I took a ford bellhousing for an older mustang (has linkage operated pivot, not cable but I am sure both would work) I milled off the tranny side so that there was exactly 3" left which is just enough to fit the clutch and starter, you could do maybe a 1/4" less or more but there was the space where the release fork sat and it seemed to put the audi release bearing in the right spot so ..... I then bolted it to the back of the motor with the ford flywheel and clutch installed and measured (hopefully right) where the input shaft would be centerd on the clutch, this is what i came up with, i forget, now i need to remeasure, but if i remember right i took 3" minus 11 mm off the end of the audi tranny then milled the supporting ribs only down an extra 1/2", then layed down a 16" peice of 1/2 6061 aluminum (lots of waste) and traced out the shape of the tranny, cut it out with a jig saw so that the tranny slips right in to the plate and is flush with the other side of it. That is as far as i have gotten due to newborn son and slotcar racing (scalex gt40) have taken up some time. The next step is to clean the case really good, i have been using muratic acid, seems to work but i dont have the guts to leave it on more than a minute, and 3m scotchbrite type wheels on an airdrill, then clamp audi and plate to a 1" thick peice of steel and have it welded, when it is done i will set it up in the mill and true up the plate. When i get my lathe working i will set up a peice of solid bar and cut it to fit tight where the pilot bearing goes and into the tranny where the input bearing would be, build a jig the right height to support the plate even with the ford bellhousing, bolt it all to the motor and clamp it and have that welded. Finally i will set it back up in the mill and true the bellhousing mounting surface. I have no idea if it will work but part of the fun is the journey, the plate cost $100 cdn and so was the tranny (thats free in usd) so i wont loose too bad i guess.
the only thing i wish i did was to not cut down the lower "t" shape brace at all untill i had it fitted because the way it all lines up the bottom of the audi bellousing (above the brace)lines up almost perfectly with the bottom of the ford bellhousing so you could leave that brace long and weld it right to the ford bellhousing without the plate in between at that point. I have pics but nowhere to host them so if you want email me and i will send them to you. When i am done i will confirm measurements.
ps. i havent figured out the clutch yet but i do have another goofy idea, which i will share if someone guesses or it works, whichever comes first.
[email protected]
[ February 26, 2003: Message edited by: Eric ]