Gary's Track Day/Fast Road Weekend Car 1zz Turbo.. Now Built 2zz Turbo with E153

Alex Knight · May 27, 2023, 12:12

Flat floor is mega.

Would you be open to sharing the templates?

Gaz2405 · May 29, 2023, 09:47

Chocks needed to get out of the garage now.

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Splitter testing today, even though I know it holds my weight, I'm still nervous 😂

Gaz2405 · May 29, 2023, 09:47

Quote from: Alex Knight on May 27, 2023, 12:12Flat floor is mega.

Would you be open to sharing the templates?

Yeah no problem, next time I'm underneath I'll grab the dimensions.

Gaz2405 · May 29, 2023, 11:24

Testing not going so well.....think the gearbox has shat itself.

Awaiting recovery.

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Gaz2405 · May 29, 2023, 13:14

Limped it home.

3rd gear has left the chat.

jvanzyl · May 29, 2023, 17:49

Quote from: Gaz2405 on May 29, 2023, 13:14Limped it home.

3rd gear has left the chat.

ah no man.. sorry to hear that.

You just going to source another stocks one or go for something fancy?

Call the midlife! · May 29, 2023, 18:16

Quote from: Gaz2405 on May 29, 2023, 13:14Limped it home.

3rd gear has left the chat.

You know it was only a matter of when 😂

Gaz2405 · May 29, 2023, 18:17

Quote from: jvanzyl on May 29, 2023, 17:49ah no man.. sorry to hear that.

You just going to source another stocks one or go for something fancy?

I've currently gone down a rabbit hole researching the VW 02M gear boxes.

Thinking of using, the zurawski Motorsport driveshafts and linkage adapter, after making a bell housing adapter.

Gaz2405 · May 29, 2023, 18:18

Quote from: Call the midlife! on May 29, 2023, 18:16You know it was only a matter of when 😂

Alex Knight · May 29, 2023, 18:25

Quote from: Gaz2405 on May 29, 2023, 09:47Yeah no problem, next time I'm underneath I'll grab the dimensions.

Mega, thanks so much.

Gaz2405 · May 30, 2023, 13:43

So I have a few options open to me in the gearbox side.

Now I want it to be as plug and play as possible, as I still want to get some tracks days in this year.

1. I've got the potential of a UK owned E153 conversion kit, with or without a rogue rebuilt E153. Sourcing an E153 isn't an issue at the moment.

2. Jubu gears, at £1k plus labour(although I'd most likely don't myself)

3. Chuck in another standard box and cross my fingers. Although they seem to have jumped in price recently.

4. 02M/Q gearbox from VAG, using the mount and drive shafts from zurawski Motorsport, but would require a custom clutch disc or find one that works with my current set up.

I'm currently torn between option 1 and 4, I need to contact another guy in the UK who is using an E153 on a 2zz turbo to see what his opinion of the ratios are.

Either way car is getting sorned tonight!

Gaz2405 · May 31, 2023, 09:01

Deal is done.

Collecting an E153 Box and conversion kit, its an early conversion kit never fitted so will need some modification to make work, as the brackets just came as laser cut steel to be tacked and welded once in situ.

It doesn't have the 1000hp rated axles just some standard MR2 turbo jobbies, so need to look into converting the outers or using different hubs.

Box has just been rebuilt by Rogue.

But we have a solution!

Alex Knight · May 31, 2023, 15:57

Could VAG DSG have been a (costlier) option?

Gaz2405 · May 31, 2023, 18:36

Quote from: Alex Knight on May 31, 2023, 15:57Could VAG DSG have been a (costlier) option?

I had quoted up two ways of doing it.

1. There's a guy on Facebook fro SA that does them. £1950+ an engine for him to use, plus the Gearbox, driveshafts etc.

2. Use the Zurawski motor sport mounts and drive shafts. Waiting for a price on the mounts, but the driveshafts are £800, plus a box and getting it working and a bell housing adapter.

I'd this E153 hadn't come up at ok money, I'd have probably gone down the zurawski Motorsport route using an 02M box first then sorting a DQ box afterwards.

But both of these options still require a differential.

1979scotte · May 31, 2023, 19:05

Hope you like the ratios dead short from memory worse than my mk2 na box on my v6.
That had an extended 5th for motorway cruise.

Gaz2405 · May 31, 2023, 19:33

Quote from: 1979scotte on May 31, 2023, 19:05Hope you like the ratios dead short from memory worse than my mk2 na box on my v6.
That had an extended 5th for motorway cruise.

From what I can see the ratios will be shorter than what I've currently got but longer than a 2zz box.

At 8250rpm should be:

1st 41mph
2nd 69mph
3rd 105mph
4th 144mph
5th 181mph

I'm not too concerned.

Gaz2405 · June 1, 2023, 22:05

So back from picking my bits up, nice 400 mile round trip.

Box is in cracking condition, rebuilt by Rogue a few years ago and never fitted.

Been rebuilt with a TRD LSD too.

The conversion kit itself, is wait for it......

A Roque Motorsport kit, very few were ever made.

Coms with laser cut mounts that need welding up.

Also comes with a twin disk clutch for mega power.

Bell housing adapter is stainless and looks a great piece of kit.

Two very good condition MR2 turbo shafts, and apparently the st185 CV outers fit roadster hubs.

I'll have to fab up the linkage's but that shouldn't be too hard.

Gaz2405 · June 5, 2023, 10:44

A little bit more parts collecting and ordering over the weekend.

5 speed selector shaft from JSpec.

Also some more info on the twin disc clutch, its the Xtreme Twin disc for the MR2 turbo and has a torque rating of wait for it............................885ft/lbs!

Think we'll be ok with this one!

Gaz2405 · June 6, 2023, 21:04

Started the process of doing the gearbox tonight.

Got the car in 4 jack stands in the garage.

Rear wheels off, hub nut off, oil drained, drain plug back in, OS arms off, caliper tied up out of the way.

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Fluids a lovely colour with plenty of metal in it!

Just waiting for an engine stay bar to arrive to take the weight of the engine, rather than my ghetto set up of a ratchet strap around the strut brace.

This E153 deserves to be installed with at least some precision!

Gaz2405 · June 8, 2023, 10:20

Grabbed half an hour last night, NS hub off.

Drive shaft out, NS drive shaft tonight.

Currently looking at trans cooler set ups and thinking about this one.

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Before I fit and weld up the bracket and bell housing adapter I may get a few copies made if there's some interest?

Nvy · June 8, 2023, 11:25

What was included with the kit from Rogue?

Gaz2405 · June 8, 2023, 11:36

Quote from: Nvy on June 8, 2023, 11:25What was included with the kit from Rogue?

3 engine mounts, bell housing adapter and custom flywheel.

Gear selector mechanism looks easy to copy from the MWR set up.

Nvy · June 8, 2023, 17:19

Quote from: Gaz2405 on June 8, 2023, 11:363 engine mounts, bell housing adapter and custom flywheel.

Gear selector mechanism looks easy to copy from the MWR set up.

If you can share any pricing in a PM would be great

Gaz2405 · June 8, 2023, 19:02

Quote from: Nvy on June 8, 2023, 17:19If you can share any pricing in a PM would be great

I'll get some prices from a fab shop.

Gaz2405 · June 8, 2023, 19:08

So all drives shaft out now, engine support beam is here too.

Got my assortment of parts out and gave them a once over.

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Box is a big beggar and was a bugger lifting out of the boot in flip flops 😂

Need some new outer CV's apparently st185 fit the roadster hub.

But apart from that we're nearly there fe more buys to collect, but I'll most likely do a dry run of the fitting the box first and go from there.