02a tdi reduction gear starter to 091 diesel bell housing

[13 window deluxe]

i was looking for a way to run the shorter, thinner, lighter,easyier to find and most importantly cheaper vw golf tdi 02a starter motor on my bay camper i have fitted with the 091 t25 diesel bellhousing as i am limited to room above due to petrol tank shelf as i have set the gearbox at the original angle with the new tdi engine fitted.
here's what i came up with:

this is what i got back from the machine shop a adaptor plate to hold and centalise the smaller nose'ed golf starter


i then cut the outer shape and drilled, tapped & countersunk the mounting bolt holes as you can see here


this is the starter adaptor plate fitted to the bellhousing with countersunk bolts


starter motor fitted to adaptor plate/bellhousing


a picture showing the old and new starters side by side


i have got all the starter and flywheel bits now and will be refitting the 1.9 tdi engine to the van within the next few weeks and then i will be able to tell you if it all works ok
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1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,

previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi

[Bugsy_malone 666]

well that looks pretty neat!

Couple of questions:
firstly how thick is the piece of aluminium you used?
how did you know this would be the right thickness?
What diameter hole did you have cut for the starter?

that way I can get my bits together so that soon as my motor arrives I can install also

cheers for letting on another great secret to an engine conversion
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Second Gear All The Way Baby!

Doing Thing Differently.

[13 window deluxe]

no1: the plate is steel and is 15mm i belive i've had it about a monthso i'd check first before making one!
no2: i measured the starter pinion lenght from the mounting face to gear end on both starters and took the shorter measurement from the longer one and the difference is the thickness of the plate.
no3: i can't remember the exact measurement, i took the two starters too my man and told him too make the hole fit the starter.

when you've done the conversion tell me how it goes as i wont be using it for a while as i dont have a turbo or manifolds till vanfest or a wiring loom made and ecu sorted
_________________
1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,

previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi

[Bugsy_malone 666]

Ah the one I'm getting looks like the nose end is slightly shorter, I hope its got the right number of teeth? I see theres a few different types but hell lets see what works!
_________________
Second Gear All The Way Baby!

Doing Thing Differently.

[Bugsy_malone 666]

ok well I have sort of tried mine out on the engine but havent checked it over properly, the thickness of aluminium I have used is 12.7mm (apparently as thats what I bought) It seemed to do the job ok, Mines slightly different in design and made at home with a holesaw but essentially based on that, I need to actually check through the little timing hole to see how much throw/clearance I get on the gear by disconnecting the motor cable and just activating the solinoid. the thing will be if it actually fits in the van!
_________________
Second Gear All The Way Baby!

Doing Thing Differently.