Caddyshack

I am going to probably get my mate Al, "the transplanter" to help with the final fit so he can double check the process and look out for any issues. He was trained by Ford when Cossis were new and has made his living converting cars and fabricating parts ever since....sometimes it is nice to have a second opinion.

It looks like you will be up and running soon.

M K

iTrader: (9)

Always helps having an extra pair of hands just that I work nights a lot and usually nobody around to help me ,

Think I will struggle with the extra weight of the skyline box on my own but il try it lol


Got my skyline clutch alignment tool through today so I can fit the new paddles and line the clutch back up on the flywheel,

Also just dropped off the props to be sorted and should be done for next Wednesday

All coming along nicely so far

Thanks
Marc

ossie cossie

I wil have maybe have to make 2 rear props one for the standard rear diff and a custom made one for when I do the supra diff conversion. Just can't seem to make up my mind. I really want the supra diff put in. But time is getting on. And I have an escos prop in the garage. The only thing stopping me is I have another COSSY and the standard bits would come in handy for that if ever I brake anything.

ossie cossie

If you get custom shafts made up and you want to sell the ones you have made already I would love to take them off your hands.

ossie cossie

Not just the props but any prototype bits you have done for the skyline box conversion. As I can see your workmanship and quality are second to none. But I don't mind the odd bodge part on my race slag. .

M K

iTrader: (9)

Il help where I can mate but most of my stuff inc props etc will be different due to being in a fiesta

They are using the props I made to refresh and balance etc so won't have them to spare I'm afraid


Had a few issue aligning the box as said before where it has warped during welding and the holes are slightly out now for the dowels so to hold the box in line I made up some alignment studs to guide the box on, hold it and allow me to bolt up both box holes onto the dowels then the bottom holes then remove dowels and finish bolting up

Makes life a lot easier







On with aligning the clutch pack now

M K

iTrader: (9)

Cut out for exhaust tunnel as want to keep to exhaust high up and the skyline box wouldn't allow that without this

Caddyshack

Great pics and the aligning tools are a good idea! Looks like we both have a similar problem lining up although I can do the first bit easily, it is when I introduce the paddle clutch and input shaft I struggle the most.

M K

iTrader: (9)

I have yet to try a fully built up skyline box but will soon enough lol so im sure il struggle just the same as you

whizzisat114

iTrader: (2)

Great progress Marc

KH

This car is amazing, you got real skills Marc

M K

iTrader: (9)

Thanks guys

M K

iTrader: (9)

Decided to get the messiest part out the way today which was cleaning up all the metal around the holes where I'm going to weld in new sections, it made a right mess but all done now so tomorrow I think il start cutting and folding the new pieces if I get a chance

All cleaned up







Doesn't look like much done but that along with cleaning up afterwards took me 5 hours

Fudgey

iTrader: (4)

Great progress Marc, it must be quite disheartening to cut bloody great holes in the shell after its been painted. At least its only relatively minor adjustments..

M K

iTrader: (9)

All for the greater good mate,

It was painted nearly 4 years ago so time for a rattle can refresh lol


All joking aside it was annoying to have to cut but hopefully the skyline box and a bit more piece of mind will be well worth it

COLEYST200

iTrader: (3)

As said mate it's a shame you have had to cut the tunnel up so much but needs must and it will be worth it when it's done . Just sorry to say it but then it will be the next weakest part with your bhp you have got . The rear diff as you well no I'v only got 400bhp and I'v smashed two diffs a 7.1/2 and a 7 .
I'v just sent my rear beam in to be powder coated and arms as I'v modded them to hold the suppra 3.9 diff . When it all comes out I'm going to have a new prop made and loose the center bearing .
Keep the good work up mate your doing a fab job

M K

iTrader: (9)

Yeah coley I've wondered about the rear diff so will have to see although I have more fair in that then the standard box lol, it's a gripper rear diff with shot peened and super finished CWP but as you found out it's the planet gears that don't last

As I have no beam to worry about, if I look at changing diffs il try and look for something even stronger than the old supra item if there is such a thing with the right ratio

ajamesc

I've a gripper diff in mine but changing to a supra one. Your not brake the gripper diff it's self but the c.w.p is made of glass lol they don't like high torque. I ripped the teeth off mine flooring it off a roundabout in second I've r888's on mine and it just gripped! Mine now has a hewland shot peened and super finished c.w.p but the diffs worth a fair bit so I'd rather sell it and fit the supra one

ajamesc

There is stronger! What rod has if he can't brake his with over 600lb/ft from low down no one will! The ford 9inch is the other one but really expensive

Caddyshack

Isn't the 9inch over Ł3000? I don't know of anyone on here breaking a supra diff in terms of the gears, just the casing where it needed a rear cover...as yet nobody has Broken a covered one tha I know of.

markk

iTrader: (2)

The problem with the 7.5" and 7" diffs with the planet gears is there are only 2 of them.
The gripper and any other good diff has 4 of them.

I think that rear will be ok for a while.

ossie cossie

On the supra diffs is the torssen LSD better than the standard clutch pack LSD?

Caddyshack

The maxi weir kit is what most upgrade with, that's what Bara put in mine.

gus

iTrader: (1)

Why dos no one use the skyline diffs?

I know the pikes peak rs200 has them front and rear

Caddyshack

Don't know. Makes sense. If I was building from scratch I would now consider skyline for engine too, that or Mitsubishi evo engine and gear. Nothing comes close to the history and nostalgia of a Cossie though.

stu21t

It's funny you say that,
This guy
[img]https://turborenault.co.uk/attachments/9055/[\img]

Is using an evo engine with cossie gearbox and diffs.
I've asked why he doesn't run a skyline box with supra diff and he's happy with the cossie stuff he's got.

Caddyshack

Cossie stuff is fine until you make 400lb ft at a decently low Rev range and the add some grip...if it were 2wd on road tyres I suspect you would be fine.

Rwd fiesta

I'm building fiesta with skyline diffs

c20tbo

iTrader: (1)

We all get hooked up on fancy diffs etc, been there done that with 9" stuff, im now on a 7.5 atb and quaife thickwall gripper new DPE box and will be at around 600bhp in an escos, id stick with what your doing/have Mark.....

ajamesc

Hooked up or not the 7.5 inch ford c.w.p is crap and will brake with high torque if it don't you have no high low down torque lol

COLEYST200

iTrader: (3)

Any updates of this weekends work mate

M K

iTrader: (9)

No updates as I've had the bank holiday weekend away from the car for a change, will be back on it tomorrow where I hope to start welding in the new sections for transfer box and exhaust tunnel as I borrowed some argosheild light off my brother in law today for my mig

c20tbo

iTrader: (1)

Possibly if your 2wd with everything hit to the rear, im 4x4 with 60/40

M K

iTrader: (9)

Needed to straighten up the tunnel as it all went out of shape 1 side when I cut the piece out for exhaust tunnel so used a brace bar tacked in until filler section was done

Nice and straight

M K

iTrader: (9)

Only had time to weld in 1 piece, will make to end pieces tomorrow





Not used a mig in a while lol

Caddyshack

Will you weld from both sides or just top? I did both sides on mine with 2 mm steel and I don't ever want to weld under a car again if I can help it! I assume that as long as it penetrates well you only need one side?

RUBY123

iTrader: (2)

what is that red/orange stuff you dot on all your bolts

Carlos-Titx

You put in on the nut and the face it sits on once they're torqued up.

So you can easily see if it's unwound. I think.

CozzyKing

iTrader: (2)

Those welds are a thing of beauty, being able to weld like that myself for me would be amazing.

M K

iTrader: (9)

Thanks CozzyKing


Exhaust tunnel section finished,

Toby - I did end up welding both sides for peace of mind





Will get a good brushable seam sealer over all welds before paint,

Gonna start on other side now