Cally AWD retro fit (56K warning)

[Peachprformance]

Well some of you know and some of you may not, but I have been planning converting my 2WD cally into a AWD tarmac shredder for a while now.

Previous post of parts being fitted :Wohoo! Got the last bits to finish my car today

Well I started it today, All the seats, carpets and soundproofing are out (so I can weld in the prop mounts without anything catching fire... hopefully).
Removed the exhaust system complete


Recut the threads for the rear driveshafts


Disconected all the brake lines, fuel lines, handbrake cable etc.


Removed the rear subframe assy


Offered up the Senator rear LSD.......... Bugger. Breather pipe on top of the diff is further back. o.k. No probs I thought drilled out clearence hole.


Offered up the Senator rear LSD.......... Bugger! Bolt holes line up but diff casing is taller. Found some new longer bolts (same strength rating) and cut some spacers from a steel bar on the lathe.


Offered up the Senator rear LSD.......... Bugger!! End casing (where it mounts on the Senator) is longer and won't clear the fuel tank! Spent the next hour progresively cutting more and more of it away.




Note. I now have a nice big hole in the end plate but a mate of mine is an ally welder and is picking it up tommorow to plate the hole for me.
But it now clears the fuel tank


Once I get the diff cover back, Should be about 11.00 in the morning. I can refit the rear subframe etc. and start on the front. More piccies to follow

[stt]

is the rear diff ratio on the senator LSD the same as that on the cally front diff?

[WeeKenny]

brilliant its good to see some new ways of doing things

[GazTaylor]

Dude, just outta interest, why ya doing that

[spanishfly]

You using the VX TX box?

[Nemesis]

You using the VX TX box?

He's using a VTS locked box

That's some serious modding

[Peachprformance]

is the rear diff ratio on the senator LSD the same as that on the cally front diff?

Depends on the model of Senator . It has to be from a 3.0 24v (and not all of these are LSD although they are supposed to be). It can't be the estate version as it has a different ratio of 3.9/1. It has to be from the salloon which is a 3.7/1 ratio.

brilliant its good to see some new ways of doing things

Cheers chap , thought up the idea about 3 years ago, but couldn't afford the bits and its been a right bugger finding the senator diff

Dude, just outta interest, why ya doing that

You using the VX TX box?

He's using a VTS locked box

Yup thats right its a VTS box going in. Had a big discussion on here about the pro's and cons' of the VTS box. If you can make it to the end of the thread it is a good read. Locked 4x4

That's some serious modding

[spanishfly]

Nice one mate

[Benn]

this will show i know nothing of rwd,but...
why use the Senator rear LSD,why not just cally turbo stuff?
then its a stright swap surely...much easyer?
ben

[Nemesis]

this will show i know nothing of rwd,but...
why use the Senator rear LSD,why not just cally turbo stuff?
then its a stright swap surely...much easyer?
ben

Good point

Peachperformance - explain yourself! lmao

[Mazz]

Wow, nice project dude. Any ideas when it we will see at a WM meet?

[stt]

my guess would be that a LSD for a cally turbo would be a lot more than the £100-£150 you can pick up a senny one for!

Plus if its good enough for a Lotus Carlton, It'll be fine on the Cally

[Nemesis]

Rear diffs don't fetch much TBH. £40-50 at a breakers or on eBay.

Perhaps it's something to do with the slip effect or torque rating (as the Senator is 2WD)

[stt]

24v Senator/carlton diffs are all LSD's and will easily get £100

[Benn]

so its just for the lsd?

si any gen on that restricker yet?

[stt]

I took it off on thursday but havent managed to get to a post office when its been open yet!

[Benn]

thats cool
thanks mate

[DarrenH]

top marks for engineering and the "have a go" attitude, but why would you not start with a 4x4 in the first place ? a cheap turbo with lunched tx box or similar ?

the carlton diff is a cool idea, they are plate diffs right ?

[Peachprformance]

top marks for engineering and the "have a go" attitude, but why would you not start with a 4x4 in the first place ? a cheap turbo with lunched tx box or similar ?

the carlton diff is a cool idea, they are plate diffs right ?

Yup, the senator diff is a plate type LSD and a lot stronger.

As for the starting with a 4x4, well thats mainly due to the fact I first bought my cally 7 years ago when I was working at VX. I Then waxoyled inside and out of all the box sections so there is no rot in it. Also their there is so much extra wiring in it for the ice, and then the alarm. Also its only done 56k from new so scraping my shell and using a 4WD one was not an option.

Wow, nice project dude. Any ideas when it we will see at a WM meet?

Coming to a meet near you soon

Anyway I'm afraid there is not much progress today as I've spent most of the day at my mums with my sister and brother (who is visiting from Sweeden). So all I've got done was to clean up and paint the rear diff casing and diff after weldiing and fit it back together.

[Opel_Dan]

looking good - looking forward to seeing more pics and getting feedback on how it drives

[stt]

Nice welding!

[Peachprformance]

Update on todays progress.

Senator diff' finally bolted in to the rear subframe assy' and Powerflex rear anti-roll bar mounting bushes fitted. You can see the spacers above and below the subframe.



I used the engine hoist to lift the rear assy' up onto axle stands, which then allowed me to pull the hoist out the way so I could get the gearbox jack underneath.



Wohoo! Rear suspension all back in, brake lines, fuel lines, ABS all reconnected and rear driveshaft's fitted.



Starting on the front end. Trouble with modified motors is that there is no bloody room lmao . Charge cooler, Top hat, etc. removed to gain access to the gearbox bolts etc.


Engine brace in place, ready for subframe to come out.


Driveshafts, Subframe and gearbox removed.


Original subframe on the left (wishbones removed) and 4x4 one on the right. You can see that the cross brace on the 4x4 one is 4 inches further back.


4x4 subframe offered up into place. Fuel line's need to be removed and bulkhead cross member needs approx 8 inches width ways and 3 inches (can't remember exactly as the measurements are at work) height taken out out of it and then welding back together. Also a 4 inch diameter hole needs taking out for the prop' to run through.



Fuel pipes disconnected, moved and pluged. Bulkhead marked up ready for cutting. Unfortunatley you can only see the yelow chalk marking roughly where the prop will come through in the photo.


Decided it was a bit late to start cutting it out and welding it tonight so came home early to sort the photo's out. I swear it takes just as long as doing the job lmao

[lethal]

Bloody hell, thats a solid looking diff

[Peachprformance]

Don't think I should be able to break it in a hurry.... Touch wood lmao

[Ginge]

Looking good one of the more interesting piece ive read on here in the last couple of years ... Cant wait to read how it drives... keep up the good one glad to see someone taking on what looks like quite a project.

Ginge