It doesn't happen very often, but half an hour ago I was bored. To pass the time I decided to lift some of the progress pictures off my phone and post them here incase anyone gives a crap about what I've been up to for the last month
For those that don't know, I own a 16v turbo R5 that I use to compete in whatever drag race events I can con my way into.
Engine wise I'm happy for now. This year it was making about 550hp from a garrett GT35/40R and quite a lot of boost. That was being fed through an old 02J 5 speed VW gearbox, hugely more capable than the original Renault gearbox but still I was able to smash gears on a couple of occasions. It also had the slowest synchro's at high RPM I've ever come across, so bad that I could shift quicker in my old citroen xantia diesel, so it had to go.
After much reading I decided to press on with yet another gearbox conversion. This time I've built a 6 speed Audi 02M (found in the Audi TT, RS4, Golf R32, etc). They're hugely stronger, have better bearings, better casing, bigger diff, bigger clutch, bigger output shafts, bigger inner CV's and most importantly they have synchromesh's that can shift gear above 7500rpm !
I built a gearbox from a mix of ratios and diff to suit my racing and set about installing it.
First up, the old 02J before I pulled it out:
I ordered a new 240mm billet flywheel from the USA, unwrapped it and set about welding it up. I milled off the weld to form a blank:
Then I drilled the renault crank stud pattern to fit it to my engine:
I also bought a new SPEC drag clutch from the USA rated to over 600lb/ft, but forgot to take a picture of it.
Gearbox installed and a new solid gearbox-to-chassis rail mount manufactured and fitted:
Since the new gearbox is 6 speed I had to make some new gear linkages. I couldn't be bothered removing the old 5 speed cable shifter out of the car so I modified the 5 speed cables to accept some 8mm rose joints and then made it all fit onto the 6 speed mechanism:
Rear engine mount was made and the lot was bolted down again:
Because the new gearbox is so large compared with the old one it ment that nothing else would fit back into the bay. I needed to make a new exhaust manifold and downpipe to clear the bigger casing. This gave me opertunity to improve on the manifold design. I won't bore you with the details, but it should work a lot better:
I also decided to chop up the front of the subframe and move the cross member down 120mm or so to mount the radiator lower down. This should give me adequate clearance for the new inlet manifold and larger plenum.
You may also notice I've chopped about with the bulkhead a bit, to give me more room for the new exhaust manifold. I was sick of not being able to get spanners onto stuff at the back of the engine, so that needless "boob" in the bulkhead got, er, mastected.
And thats all for now
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think you have deserved a 
, hope the O2M serves you better. Clutch sounds like it might be up to the job! The flywheel looks sweet too.
Originally Posted by Woznaldo
keep up the good work son 
Quality 
