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 1973 96v4 with a modern twist
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AnttiK
V4 Beginner

Finland
68 Posts

Posted - 07 May 2021 :  07:07:27 Show Profile Reply with Quote
Looks like the Mini brake calipers releases the brake pads better than V4 original. There is clearly less friction when freewheeling and the improvement can also be seen from lower engine vacuum values when cruising.

I tried to refurbish the original calipers and make them operate more freely, but I think there still was some extra friction with the pads. At least in the caliper design the outer pad is not releasing very well and i.e. when accelerating there is always some minor clearance in the wheel bearing and I think the disc is pushed against the outer pad.
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AnttiK
V4 Beginner

Finland
68 Posts

Posted - 18 May 2021 :  06:14:26 Show Profile Reply with Quote
Hub conversion is now inspected by finnish vehicle inspection engineer. So it is street legal now I had to use a hammer to the rear hub cap to make some more space for rear axle.





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Derek
V4 Guru

United Kingdom
2042 Posts

Posted - 18 May 2021 :  12:43:07 Show Profile Reply with Quote
Very smart. I can't see behind the calliper but is the brake hose long enough to cope with full lock and suspension movement? Or both in extremis!
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AnttiK
V4 Beginner

Finland
68 Posts

Posted - 18 May 2021 :  13:15:23 Show Profile Reply with Quote
Yes, it is Opel Astra / Saab 9-3 320mm hose with banjo fitting in the caliper end and there is enough length or even too much length. The original hose length is about 250mm, but because of banjo fitting hose must be longer anyway.
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AnttiK
V4 Beginner

Finland
68 Posts

Posted - 16 Jun 2021 :  18:47:12 Show Profile Reply with Quote
Balance shaft gear lost its teeth and I decided to purchase new hybrid gear set from Motomobil. At the same time I decided to change to flywheel trigger. 36-1 pattern was milled to flywheel. Actually the size of the teeth became quite huge in the end, but main thing is that the trigger works Those did not look that big in CAD program.



Sensor was installed to clutch bellhousing:


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I can see the RPM signal is now more stable. Not dramatically, but clearly less ripple.

At the same time I installed Peugeot 306 2.0 hydraulic engine mounts, which are about 30mm taller than the original, so engine mounting brackets had to be modified. And now there is clearly less vibrations. Probably mostly because of improved engine mounts and maybe a little because trigger wheel (extra weight interfering the balance shaft) is now removed from balance shaft pulley.
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melle
V4 Guru

United Kingdom
3390 Posts

Posted - 17 Jun 2021 :  10:05:51 Show Profile Reply with Quote
Nice! My initial idea (of which I've never really researched the feasibility) was to place the VR sensor sideways just above the starter, but your solution is much easier and neater.

www.saabv4.com
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AnttiK
V4 Beginner

Finland
68 Posts

Posted - 17 Jun 2021 :  11:03:14 Show Profile Reply with Quote
quote:
Originally posted by melle
Nice! My initial idea (of which I've never really researched the feasibility) was to place the VR sensor sideways just above the starter, but your solution is much easier and neater.

www.saabv4.com



I probably would have installed the sensor sideways above the started in the first place like those are usually installed in the cars I have seen. But this time I had to make pattern in this way, because flywheel was already lightened and there was no material left in flywheel to make pattern to that direction.

If I had used stock flywheel I would have made the pattern sideways, because there would have been need to remove less material in that case.

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melle
V4 Guru

United Kingdom
3390 Posts

Posted - 17 Jun 2021 :  11:13:12 Show Profile Reply with Quote
That's a good point, but I still think what you've done is easier because it doesn't require any modifications to the bellhousing. I think with your pattern a sideways sensor should still work, but I don't see any benefit over your current set-up.

With the sensor in that position it's also fairly easy to just drill a series of holes in the flywheel if you don't have access to CNC equipment, much easier at least than drilling a hole pattern in the side of the flywheel. Like this:



www.saabv4.com

Edited by - melle on 17 Jun 2021 11:15:41
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Borstlap
V4 Fanatic

Norway
303 Posts

Posted - 17 Jun 2021 :  16:44:41 Show Profile Reply with Quote
Potential downside of that construction is that you run the risk of losing signal in case of backlash of the crankshaft. I read someone with a Beetle experienced this. The backlash was not more than 0,2mm, but the temporary signal loss caused very erratic running. But maybe there are sensors that are more sensitive than the ones that are normally used on Ford Edis 36-1 setups.

Alex
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melle
V4 Guru

United Kingdom
3390 Posts

Posted - 17 Jun 2021 :  17:21:34 Show Profile Reply with Quote
Interesting point Alex, if I remember it next time I'm in the workshop, I'll measure the crank backlash on a few engines.

www.saabv4.com
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AnttiK
V4 Beginner

Finland
68 Posts

Posted - 17 Jun 2021 :  18:07:08 Show Profile Reply with Quote
At the moment VR sensor is about 1.5mm away from crankshaft tooth. I would guess it would work at least +-0.5mm crankshaft longitudinal play. This could be verified by removing/installing shims under the sensor and making the measurement with tunerstudio toothlogger.

0.2mm play sounds very small and I would guess the sensor distance from trigger wheel has not been optimal.
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AnttiK
V4 Beginner

Finland
68 Posts

Posted - 17 Jun 2021 :  19:07:35 Show Profile Reply with Quote
Here they install the sensor typically with 0.5 - 1.5mm gap to trigger wheel. If I understand correctly they do not recommend it to be installed like in the picture (and like I have installed).

https://www.efignition.com/c-3632495/crank-position-sensor/

Edited by - AnttiK on 17 Jun 2021 19:08:16
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Borstlap
V4 Fanatic

Norway
303 Posts

Posted - 19 Jun 2021 :  19:13:41 Show Profile Reply with Quote
I reread the topic I found on the troublesome signals and there were more issues in the setup; best to read everything without me in between forgetting or making up tings : https://forum.autosportlabs.com/viewtopic.php?f=7&t=5413

Alex
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AnttiK
V4 Beginner

Finland
68 Posts

Posted - 08 Jul 2021 :  12:18:30 Show Profile Reply with Quote
Have driven few hundred km's with Peugeot 306 hydraulic engine mounts and I think those are very good improvement Much less vibrations now. Few pictures:







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PYM35
V4 Beginner

France
94 Posts

Posted - 22 Aug 2021 :  10:00:09 Show Profile Reply with Quote
Hello AnttiK,
I'm amazed by the great work you share with us and you're knowledge that allows you to experiment the usage of other car make parts !
About the 306 hydraulic engine mounts : do they fit with no modification on the V4 platform ?
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