Been messing with the aef diesel engine in the felly pickup and looking for a race/rally type clutch. Favorits and felicia that raced (some still do) will possibly have a decent friction plate that will fit. Anybody know stuff around this. It seems the clutch set up is unique as it has a vw engine and skoda type box. ---- The engine has been converted with tdi head,pistons and rods, fuelled by a discovery pump and aspirated via a vnt 15 turbo on a 80mm straight thru exhaust . It was to have an 02a gearbox and vr6 clutch but the box disappeared from the back last week. Std box is ok with 15" rims but the clutch slips on boost. Engine puts out an estimated 120 bhp. Ideas help please.

There are often paddle clutches around on various CZ-based sites, so I'd think that would be the place to start looking; not sure what size the Diesel clutch plate is though, in terms of OD?

how are you modulating the boost pressure on the vnt?

the std skoda gearbox wont like it for long mate.. i did a similar conversion but with a smaller wastegated turbo, it will damage the splines on 3rd and 4th gear if used much clutch is 200 mm diameter but i would think it needs to be around 220mm really to be able to take the torque,

i would try for another 02j box and flywheel as shafts are easy to fix (pm me if you are stuck on the shafts..

the skods cv;s wont take it for long either

Thanks for replies. The skoda box obviosly wasn`t the first choice and the torque won`t do it any favours, but as its there I`ll set the engine up abit as is. Just bought a new std clutch for a look (I left the aef block in situ and swapped head, pistons and rods cos the engine lift wouldn`t move about on the ice field I was working on(in). It`s 200mm and unique in all respects sizewise.------At present the turbo has a mechanical system. A spring holds the vanes open at rest, a cable is fixed to the accelerator on the pump link and via different weight springs closes the vanes as the accelerator is pressed. Boost is connected to a pressure actuator that overides the closing springs, at present at 1bar. Lots of trial and error (lots of error) but its functioning reasonably well. ------------------ I`ll definitely be in touch about the shafts. Cheers rolo

why did you change the pistons and head mate? i take it you are now running direct injection?

i just bolted a golf turbo manifold and pump to the sdi and made up the oil pipes (and wound the fuel up a tiny bit!!!) that was just about on the torque limit of the std clutch but really nice to drive and just what skoda should have done from factory..

oh with the skoda box you will run out of rpm at 96mph (just dont ask how i know that)

why did you change the pistons and head mate? i take it you are now running direct injection?

i just bolted a golf turbo manifold and pump to the sdi and made up the oil pipes (and wound the fuel up a tiny bit!!!) that was just about on the torque limit of the std clutch but really nice to drive and

jimbo have you got any more info on this?? which engine code did you get the pump and turbo from??

pm'd ya mate to avoid going off topic on here lol

Well the original motor was good and actually did that indicated 96mph economically and the first step was a bosch pump with an lda from a montego and a gt15 turbo but the cr and pistons are wrong, it worked ok but the na pistons have much thinner tops. (I run a turbo aef in another motor but with aaz rods and pistons which apart from valve seat composition is an excellent set up--- but like all turbo idi engines runs very hot (too) under load The tdi set up runs much cooler and better economically . It is going to be part of a projecf involving a reno un1 box in a t25.---- I had an ahu engine ---0.99p on ebay! the skoda is very easy to work on so why not? We`ve all done stuff for the crack or to see if we can or to see if some thing works, you know what I mean.---- The disco pump on the turbo`d na was ridiculous but fun, thats what I/We are about ,yes?---- back to topic. Ok, the new pressure plate is a stepped 1- the centre protrudes to fit into the stepped flywheel. Removal of metal from the outer section of the fly wheel will increase the clamping pressure. but how much to take off? Any thoughts/experience?--------What size wheels/tyres and revs did the running out of steam at 96mph?

Edited 4 February, 201016 yr by rolo

yes tdi is the way to go really much better all round, comp ratio was the same on the na felicia as the tdi golf so mine worked ok could have done with an intercooler tho lol. cant beat doing something just to see if it works tho your right there.

now i dont think removing material from the flywheel would help much as its not increasing the diaphram pressure but you may run into clearance problems with the cover fingers and the clutch plate (on the rallycar we used to run gpA sachs skoda pressure plate that required 2mm removing off the flywheel thickness and a skd pressure plate would foul when we tried it)

how about contacting helix clutches as they altered a pressure plate for me years ago to add more clamping force (they basically stuck another diaphram over the existing one with the fingers removed) either that of techniclutch may do something along the lines of a paddle clutch if you asked them??...

i was using the std 165 70 13 tyres on mine but it would pulled 15"'s easily

I'm with Jim on the removing material/pressure thing; unless the clutch pressure plate has a rising rate spring (and I'd doubt they do) then it won't make any difference to the pressure.

Yes I get that, I have found a man that may help with the clutch. I ran a golf tdi turbo and exhaust on the early td guise of this engine, the inlet manifold too but this required surgery as it fouled the bonnet and had to make a downpipe. As I say it worked ok but the compression ratio of of the factory turbo diesel is 0.5 lower than the aef. The CR of a tdi engine is lower again, much (around 17) because of the more efficient combustion shape and higher pressure fuel and hence runs much cooler. A tdi turbo will work on a td and viceversa.---------I will report back if the man can.---------- I was wondering about that 96mph,the std motor would clock 95 on the flat 96 downhill and 94 up,perhaps aerodynamics perhaps the govenor, its interesting that you came up with the same figure, How fast is the fastest felicia? Was the sachs plate 18 spline centre? Hope I`m not boring you with all these questions. Cheers rolo

Edited 4 February, 201016 yr by rolo

hi mate yes the sachs was for the 1.3 so a 190mm plate infact i have seen someone on ebay selling new paddle clutches for a felicia maybe worth a look?

my td conversion would not do more than 96 so i guess it was out of revs (no rpm counter), fastest felicia???well my rally car is geared for and has seen off 135 but it does get a tad light on the steering .

if you fit the later facelift bonnet ih has about an inch more clearance over the engine too.. mine fouled the bonnet but i put a spacer into the engine mount to drop the engine and a spacer on the bonnet catch so the bonnet looked like it was open a bit lol

Good info.Thanks. Will be in touch when I can get this clutch problem out of my head