help, flywheel and clutch wont fit! and progress so far!

si_c1978

does any one know wether there is an existing flywheel and clutch (although probably just the flywheel) for the z20net engine when being used in conjunction with the f23 gearbox?
the engine i have (the z20) has one of those silly soft drive clutches with the dual mass flywheel (8 hole pcd) i can supply dimensions if required,
and the origional flywheel and clutch(z22se) is some 25-30mm shallower due to having a solid flywheel (and a 6 hole pcd,)

does anyone know wether there is an existing replacement flywheel in existance with 8 holes or will i have to re-fabricate my old one? notsure.gif
help gratefully accepted!

Mark_Dj

Re: hlep! flywheel and clutch wont fit!

I am sure Neil or Daz will be able to help you out 🙂

si_c1978

Re: hlep! flywheel and clutch wont fit

right o
worst case scenario is i have to re-engineer the old one,
ive done some drawings of the rough diameter of the 6hole and 8 hole pcd' and it looks promising it can be drilled and still maintain balance without breaking thro some of the the existing drill holes,
(only a few mm tho) so i kind of need to know the strength requirements of the flywheel notsure.gif
and maybe refit the z22se the starter if the teeth are different,

vocky

it's possible that the c20xe flywheel will fit, that is 8 hole I believe notsure.gif

rushy

Dont know if its any help or makes any difference i'm sure the Z22SE with F23 has a DMF not solid in the Vectra C.

ATOM_X

saab do a single mass version of your flywheel (sweden market only)
same dimensions. so its bloody heavy
I had a lot of material removed (60%)
If you remove that much material you should get it dynamically balanced
sorry no photo's

si_c1978

on the score of re-machining the old one, here is a revised sketch with actual dim's,
i can weld the existing holes but im not so sure on how safe it would be notsure.gif
ill look into the c20 one, cheers boys!

ATOM_X

the eight holes are NOT equi-pitched

si_c1978

ok do you know how they are arranged ive got both the flywheels off and they appear to be?

ill take my verniers home for a proper measure up and if they are different ill plot em out on our microscope at work, :think:

my boss says i can have the welding bay and a machine tomorrow nite, as we've had a bit of a chat and we cant see the harm in welding it, certainly safer than cold sweating bungs in, i may re-drill the holes on a manual mill with a flat bottomed cutter, as i will have more feel,

if anyone has any safety concerns please bring em up! thanks guys! :thumbup:

heres a post from when my mate used to do my research for me that i found still on here that you may find interesting.

viewtopic.php?f=115&t=4151&p=37553#p37553

ATOM_X

zafiraz22se said:
saab do a single mass version of your flywheel (sweden market only)
same dimensions. so its bloody heavy
I had a lot of material removed (60%)
If you remove that much material you should get it dynamically balanced
sorry no photo's

Saab item is £74 plus vat + postage

slindborg

imho I'd not be fecking about welding up and redrilling the flywheel, esp when the right part is so cheap.

alanoo

Yep, strange price for a flywheel, interesting

slindborg

alanoo said:
Yep, strange price for a flywheel, interesting

perhaps they recover the cost of the flywheel from selling a cam chain kit for £700 lol

JohnnyN

slindborg said:
imho I'd not be fecking about welding up and redrilling the flywheel, esp when the right part is so cheap.

Totally agree on this. I work in a machine shop and knowing what I know about stress testing there is no way that I would be fannying about welding or bunging holes on a flywheel. A flywheel needs to be balanced and strong. Buy a new one!!

:!:

si_c1978

true but the one he is suggesting will still need machining,

JohnnyN

My concern for you is the safety aspect. There have been horror stories about lightened flywheels breaking up. I recall one such incident recently at Santa Pod where the flywheel broke up and cam back through the bulk head into the passenger footwell. That ain't going to go down very well with someone sat in the passenger seat.

slindborg

there is a small world of difference between machining material off the flywheel mass and bunging the mounting holes then redrilling.

TTV also sell saab flywheels all pre done and billet etc

BURT150

Is There no solid flywheel convertion made for them? I found they do them for fords tdci i think it was LUK? Who ever thought up DMF's needs a good poke in the eye!

si_c1978

it does seem to be thwarting my cunning plans,
we are hopefully getting another flywheel tomorrow that may do the job,
the other fly wheel was welded milled then ground,
never got round to balance testing it tho, ran out of time and at that stage hadn't checked this post to see the concerns, ill push it to one side for the sake of everyones nerves!(shame coz it looked lovely and took 3 hours! :thumbdown: )
we'll see what we can lay our hands on and re-plan

slindborg

BURT150 said:
Is There no solid flywheel convertion made for them? I found they do them for fords tdci i think it was LUK? Who ever thought up DMF's needs a good poke in the eye!

the DMF concept is great, just with everything OEM its made to a price and they arent reliable.