Hello all, can anyone point me to some how to guides for a 4x4 conversion. I would like to keep the 20vt engine and 6 gears would be nice.

Jules.

just do a search on here mate theres enough threads about it also look in the projects area

It is possible but not for a lot of power as the gears in gearbox are thinner than 4x4 and bearing and all is very fragile maybe ok for everyday use of normal person but forgot abut Launching car on LC and things like that.
You need to machine off gear from torque controller of 4x4 gearbox and machine 6 spd gear to fit on machined 4x4.

I did it like that but first gear lasted one start, and 4th gear was shaved first time with flat foot shift.
I was thinking that jtd or v6 gears would be better but found them the same quality just different ratio.

at that time i had welded viscous but return back q4 gearbox as that one have more then 1000 launches on LC and no problems at all

And modification of sump and exhaust is required.

other than that all is just bolt on

I'm happy to give you advice as well, PM me - check out my build thread

http://t124.com/forum/viewtopic.php?f=11&t=15098

Dorian - expect a PM

Cheers

This is really interesting. I did a 4x4 conversion of a 20VT a long time ago and I also intended to rebuild my 6-speed box to a 4x4 box. To do this I opened a 6-speeder to have a look to the possibilities of modification.
First I thought about the same changes as you. You would need to take the sprocket from the 6 speeder main diff, fix it to the main diff / torque controller from the 4x4 box (needs machining).
Then take the 6-speeder housing, weld a bearing point for the bigger 4x4 torque controller (need machining again), take the original main diff cap from the 4x4 gear box and screw these parts together...
This was my first thought (you did it in such a way???). But later I decided to Keep the Alfa q4 box, because it looked stronger. But I never checked the size from the gears itself?! I thought they would be equal (but I never checked with a gauge)?!
I still have a 6-speed box, because I up to now had in mind to try a conversion with streghened parts. But if you say that the original gears from 6-speeder are weaker than the gears from old 5-speeder, I can forget this possible solution?!
Juergen

The 5 speed supposed to be way stronger.. Lots of those being abused to the extreme without breaking. Makes it a no brainer for me.. 6 speed would be nice tough..

Btw Saint.. Im doing a conversion with a dedra starting this summer (originally started three years ago but you know) :o)
Looks to me the dedra tank would fit if using the boot floor of the dedra?
Got all parts from dedra exept the floor piece but that shouldnt br to hard to get hold of..

Glad to see your car coming together! Epic build

AND.. Looks like OZ racing has wheels in 8x17/18 in the et range of 15-50.. Might sort out the wheel issue..

Actually this and the exhaust are the annoying part of the conversion, as dedra or 155's tank won't fit under the coupè as its end is shorter.

It might not be such of an issue if you're fine with cutting the spare wheel well, weld a flat panel and get any compact tank from your nearest scrapyard, something dimensionally good that would fit with some minor modifications, or you can get an alloy tank that you can fit in the same place or just into the boot.

You don't want to use a six speed, as it's known to be fragile, it couldn't handle the torque of your setup.
I suggest you to save time and money and sell it straightforward.

@ saint I've seen the thread about your project and, it might be because of the color, but that reminds me so much about mine, it's a long job but I've had some good times doing it. the pleasure to ride it will be massive, so keep going on, you'll be rewarded.