2.0 HDI Lexus 6 Speed Conversion

When I started to plan rebuilding of my Jimny I was considering putting a 1.9 TDi from VW/Audi with it's gearbox, but dropped the idea of diesel engine mainly because it's weight. BMW 1.8is weights ca. 220lbs and VW 1.9TDi ca. 300lbs + gearboxes (BMW's is also much lighter than VW's).

The other thing is that big diesel engines have a lot of torque. BMW 1.8is has 140hp and 172Nm, and VW 1.9TDi 115hp and 235Nm (even before remapping) which is too much for Jimny's or even SJ/Samurai's transfer box. Lexus has 136hp and 320Nm which I would be very worried about with Jimny's transfer case. I would recommend LJ70 if you're swapping for a big diesel engine.

Reducing weight was one of my priorities, because I'm building my Jimny straight for competition purposes, hope Your diesel will work for You.

Just looking through my top trump cards and the Jimmerknee has 80 ponies and 104 torque's..... The only Lexus part I'm using is the gearbox which is 6 speed as cruising speed matters for me.....The HDI has........ 90 ponies and 205 torques in standard trim. So the earth may stay on it's axis after I try it?

One of my workmates is interested in reducing weight for competition so he's designed and made this.

Thats 30kg reduced just on the block.....1000hp and >500 torques could be handy in a competition jimjam with a sequential box no?

I'll be sure to check the rubber band in my T-case though.

Could be a good test for the new 5 axis EDM!

Omg, I misunderstood the whole thing - thought You're going to swap gearbox and engine Sorry for the mess.

Placek wrote: Omg, I misunderstood the whole thing - thought You're going to swap gearbox and engine Sorry for the mess.

No worries

First coat of paint applied tonight....modern MDF is.....very poor quality, very fluffy inside so I have to paint and leave to dry. The Ronseal cupboard paint seems to cover very well.....at least it sticks the fluff down.

Another coat and then before bashing the sand it'll get coated in "releasal" an Aluminium release agent (It actually works on naked MDF but I prefer the damp resistant paint to seal it if I'm keeping the pattern) to let the sand slide off and leave a slight refractory coating in the sand.

I use oil bonded sand which will show up fingerprints from the patterns in the final casting.

Intermediate pattern is yet to be finished as I've run out of skin and thumb nail!

great progress Keithy.

it'll be up and running in no time!

Paul.

So how does this work then?
You sit one MDF 'intermediate' mould in the other, fill the void with some kind of wax or melty substance to make a mould then bury that bit in sand and pour in molten aluminium to melt it away?