Thread: Isuzu C240 powered Series 3

Originally Posted by gromit

The flywheel from the conversion kit is just over 10Kg minus the ring gear (just need to go and clean our postal scales....).

This worked OK prior to the centre failing but I will try and increase it a bit.


Colin

I imagine the torque pulses would be hard on the flywheel as well as the gearbox, so the light flywheel may have been a contributing factor.

Checked some dimensions and offered up the old flywheel.
OD can be increased by 5mm but the ring gear is behind so it only affects roughly half the thickness of the flywheel.
It will still clear the starter by a few mm.

DSCN1248 by Colin Radley, on Flickr

The dished centre section will be shallower because the flywheel will be thicker where it bolts to the crankshaft. Plus we will change the shape of the outer edge of the recess because it only needs to clear the pressure plate.

DSCN1247 by Colin Radley, on Flickr

There will also be a centre in the flywheel machined to hold the spigot bush.



Colin

The flywheel is now roughed out but there is a small area of what looks like porosity on one side. Our machinist spotted this and hadn't turned too much off so he made this the rear of the flywheel rather than the clutch side which would have been a major problem.

Picture here shows the blank on the right and the old flywheel & ring gear on the left

DSCN1252 by Colin Radley, on Flickr

This is the rough turned flywheel.

DSCN1258 by Colin Radley, on Flickr

Final machining tomorrow then have to find someone to balance it next week. I may also have to get the clutch face ground, we'll see how the final finish looks and take advice from the company that balances it.


Colin

Originally Posted by isuzurover

4BD1 is 16-17 kg.
2.25D ~30 kg (but I am about to remove it so can measure exactly)
2.25P ~20 kg.

Sorry, my previous numbers were a bit out.

2.25D flywheel (weighed last night after removal) ~18.5 kg.
I suspect a 2.25P then is only ~5 kg less.

Murray has posted previously that his 4BD1T (truck) flywheel was 14.7 kg. Dougal's ~16 kg. My landie 4BD1 was 16.0 kg but that would have been after at least 1 round of machining.

My previous measurements:

Originally Posted by isuzurover

I just measured my landie version.
16.0 kg
390 mm across the machined face
390 mm across the ring gear
165 mm across the recess

though mine might weigh a bit less after the grooves have been machine out...

http://www.aulro.com/afvb/newreply.p...eply&p=1053126

Just re-checked flywheel weights.

C240 - Land Rover conversion flywheel 11.4kg with ring gear

C223 flywheel with ring gear 11.3kg

We're about to start finish machining and drilling for the mounting bolts & clutch pressure plate. Once it's finished I'll weigh it c/w the ring gear.


Colin

Managed to finish the flywheel yesterday, final weight 14.4kg with ring gear. Just have to organise balancing and it's ready to install.
Then I have to rebuild the gearbox....

Holes being drilled.

DSCN1264 by Colin Radley, on Flickr

Finished flywheel. Boss in centre is for the spigot bush.

DSCN1268 by Colin Radley, on Flickr

Colin

I took the flywheel to Dandy Rebores this morning because they list flywheel balancing.
I went to the counter first to check they could do the job, the guy behind the counter gave me that "oh no not another home made flywheel" look. I got it from the car and he ran his hand over the pressure plate side and commented on how well it was made.
Should be done on Wednesday, cost about $110 plus GST.

I've passed back the comments to our machinist......

Still waiting for flywheel bolts. Patterson Cheney Isuzu ordered them in, they were wrong. Then they looked in a C240 Industrial manual and found a different part number, ordered that in and it's the right one but they only have 5, waiting for the last one to come in.

I have to heli-coil a couple of bolt holes in the conversion plate plus one of the starter motor bolt holes is stripped. I should be able to fit it all back together either this weekend or next.


Colin

Hey mate will this help?????

Isuzu C240 Motor Diesel Land Rover Gearbox non turbo engine | eBay

Justin