1st post - T-5 conversion question

[jskrebs]

Your description makes it crystal clear. I will make a rotation jig for my drill press to keep the radius aligned and draw up a CAD template, print it and attach it to the flywheel. First pass will be with an automatic center punch, then with a center drill, a drill bit and finally a counter bore to flat out the bottom. How deep did you go? what diameter hole?

I believe the VR sensor triggers on the leading and trailing edge of the hole.

I noticed your 2 wide gap is filled rather than removed. Any issues as far as you could tell?

Heff

[ianrobbo]

First pass will be with an automatic center punch, then with a center drill, a drill bit and finally a counter bore to flat out the bottom. How deep did you go? what diameter hole?

Almost identical to what I did. Even with a drill press, you need to be real careful, it's easy to let the holes go off centre. I drilled 8mm holes, depth similar.

I noticed your 2 wide gap is filled rather than removed. Any issues as far as you could tell?

Heff

Interesting point. Initially it ran well with the filled gap. Then, it was pointed out to me that it should be removed, and I suspected that may be the problem with not revving aboce 3500rpm (as mentioned on my UK Saabs thread) but it turns out it had nothing to do with it. So I drilled out the filled gap, and hey presto - it didn't work! No run!
By this point I was really scratching my head, and the chance of a milled shutter wheel came up (from Saabmatt, he's on SC, and is the guru of T5 conversions in the UK as far as I'm concerned) so I took it.

[jskrebs]

So I drilled out the filled gap, and hey presto - it didn't work! No run!

Hmmm Conundrum!

So how much was the milled Shutter Wheel?

[ianrobbo]

Hmmm Conundrum!

So how much was the milled Shutter Wheel?

Got it second hand off Saabmatt when he upgraded his clutch.

[jskrebs]

Think he has the CAD file? Got a buddy with a 2500 watt laser cutter. How thick is it?

[ianrobbo]

Think he has the CAD file? Got a buddy with a 2500 watt laser cutter. How thick is it?

Don't think he has. I'll guesstimate the thickness next time I have the 900 in my workshop. It's not very thick.

[jskrebs]

Hoping it's about 1 to 1.5 mm

[jskrebs]

Drawing up my trigger wheel in the free CAD software from Emachineshop.com
It's not the best CAD software, but it's free and when I am done I can get a quote on them making it for me.

Still need to add the mounting holes and index marks for TDC and CPS sensor placement.

What do you guys think?

[ianrobbo]

Here's the best picture I've got of mine:



I reckon it's between 3 and 5 mm thick.

[jskrebs]

Trigger Wheel Updated

Curious do I have the TDC and gap in the proper orientation