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72 Hour Rivergate Conversion Challenge

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8PM and I'm tiring out. Making modifications to the transmission is kicking my behind! Something happened to my cutoff wheel when I started whacking at the extra 90 degree piece on top. I took a small hack saw to finish cutting through it. The grinding stone in my rotary piece clogged even with applying WD40 so I haven't got all the ridges smoothed out.

Cutting the hole for the starter was a pain. I went through two fully charged batteries with the hole saw. I finally had to finish with the electric drill. It's at least done now.

The recess needed for the oil pump cover is my biggest challenge. It's suppose to have a depth of 5/16". I've worked on it a good hour and a half and I'm nowhere close. I've tried grinding stones and Dremel cutoff wheels but they're just not getting the job done.

I've got another challenge awaiting me tomorrow, and that's how to get the spigot bushing out of the end of the crankshaft and the new one in. I've never had to do that kind of a job before.

I think it's time to start tidying up the garage and outside. May even try modifying the clutch pressure plate.
 
When working with aluminium, ordinary grinding stones will not work well. They will load up and not cut.
 
Sounds like a good day of progress Jim. I'd love to have one FULL day! Thanks for the updates..can't wait to see the pics! (please pass us a link when you're done)
 
Sounds great! Keep up the good work! :wink:

:cheers:

JACK
 
I knocked off at 10:30. Found some bigger cutoff wheels and used them in my drill. I think I gained 1/16"...only 4 more to go.
 
for spigot bush: thin chisel with one side ground half-round. Cuts right through, no harm to crank. Cheap bushing driver from HF to install RG bush -
 
Another way to remove pilot bush is to find a bolt that just fits in the center, a couple of inches long, pack some grease in the recess, put bolt in there and smack with hammer. The hydraulic pressure from the grease should pop the bushing out.
Bill
 
Day 2 8:45AM. Day 2 is off to a very slow start, because I'm off to a slow start. All the contortionist moves I made yesterday are caught up this morning. Still some progress made. A friend of mine gave me a tip about using a certain type of rotary bit to make that oil pump cover relief. Also I wasn't sure that the big round cover surrounding the drive shaft yolk was suppose to come out. Apparently it does, so I'll get that removed and the rear seal replaced. First, I'm heading to the store for bits and pieces.
 
You're still moving fast. And you're saying the Rivergate adapter doesn't have the recess for the oil pump already machined out? Or am I missing something?
 
The adapter has a hole for the oil pump, but the mounting face of the transmission does not. So a 5/16" recess has to be put in it. I just got back with some new bits, so we'll find out if they work.
 
With the correct bit/tool it is a 5 minute job.
 
Adavance has the proper bearing puller as a rental tool. I've used a similar bolt method, but let it drop behind the lip of the bushing and put a nut and flatbar w/ hole on the other and tightened nut and pulled it out. Basically, your making a puller out of a bolt and nut w/ flatbar across the flywheel.

The most important thing, TAKE YOU TIME WITH ALL OF THIS !!!!

Don't let it get to you and run you down, take a break when you need to.

When in doubt and fustrated, WALK AWAY for a litle while.

Trust me, I did this kinda crap for a living.

Nothing beats comming back with a fresh mind. It'll actuall save you time.
 
12:18PM Progress! Finally got the recess ground out. The old rear seal on the transmission along with the ugly surround, and the new seal installed. All holes to mount adapter have been drilled out per instructions. Now I'm working on grinding the ridge at the bottom of the transmission, and that will wrap up he mods.
 
1;25PM and all the transmission modifications are complete! I wound up using a Dremel bit 115 to get the ridges. I wish I'd had that when I started the recess for the oil pump cover! Test fit the adapter and oil pump cover and it fits. I've put sealant around the hole for the cover and around the cover itself letting it cure. There's another use for a fan belt pulley...dead weight to hold the cover down.

My next challenge is removing the pilot bushing. I can't a bolt or flat head screw to get purchase behind the bushing. I tried packing the hole with grease and packed a socket and 3" extension with grease to hydraulically push it out. All that did was make a huge mess. So should I ring my local Advance Parts place to see if they have the bushing puller, or have take a chisel to it?
 
jhorton3 said:
My next challenge is removing the pilot bushing. I can't a bolt or flat head screw to get purchase behind the bushing. I tried packing the hole with grease and packed a socket and 3" extension with grease to hydraulically push it out. All that did was make a huge mess. So should I ring my local Advance Parts place to see if they have the bushing puller, or have take a chisel to it?
Click to expand...

It's made out oil-lite bronze, pretty soft material, take a narrow chisel or punch and use the that to make a few creases in the bushing, once you get into about three pieces it will fall out, make sure you soak the new one in oil befrore installign, as ti will be made out of oil-lite as well. The grease hydraulic method of removing pilot busihing does not work mopst of the tie, nad is real messy. AS for reintalling the new bussihg I have pieces of round dowle for the different MG motors to do this, but a socket will work, it won't take alot of effort to get the new one in, I use a real input sahft for a clutch alignament tool, but the plastic ones will work. good luck.
 
Thanks Hap. I went and got the bushing puller, but it's not working. I cannot get the fingers behind it enough to pull it on out. It just keeps slipping. Looks like it's hammer and chisel time. I've had the new bushing soaking in oil all day today. Thanks for the idea on using an input shaft or clutch alignment tool.
 
I borrowed a proper puller from Auto Zone. I hooked it up and the bushing almost fell out. I probably didn't even need the puller, but had heard so much about how hard they are to get out, I didn't even try. You can also rig up a slide hammer to get them out, but sounds like the chisel method is a good way to go.
 
3:30PM and the pilot bushing is in. I'll take the bushing puller back and get my full refund. I'm taking a 30 minute break. It's a lot hotter than it was yesterday.
 
5:45 and I've got a good bit done. Adapter plate is on with sealant. New rear main seal is on, and the flywheel is bolted in. There won't be any pictures of that process because you have to use your fingers to really get a good application of that sealant in place of the old paper gasket. No way am I touching my camera with my hands like that.

Pressure plate has been modified by knocking out the center contact pad with a cold chisel. It's useful now to chuck at someone if you really get upset with them. Now I'll clean off the flywheel and get the clutch installed.
 
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