The project hits its first two speedbumps

Speedbump #1: As it turns out, I should have waited a few weeks before selling the spare 4 cylinder Scotty's Adaptor that came with the Sonoma 109. I need it now. It turns out that the Scotty's adaptor that came with our 109 is a 6 cylinder adaptor. This means that the inner diameter of the adaptor was made to fit the smaller diameter of the 6 cylinder bellhousing and was also drilled to match the 6 cylinder bolt pattern.

The new R380 from Ashcroft (which, by the way, arrived at Gord'ns shop today) uses a 4 cylinder bellhousing. The lip on the 4 cylinder bellhousing should slip inside the adaptor so that the mating surface of each fits snugly together. Instead, because the adaptor has a smaller inner diameter, there is a gap. In the pictures above, you will see our adaptor sitting on top of a spare 4 cylinder bellhousing on the left. On the right is a side shot which shows the gap between the two mating surfaces.

The local purchaser of the 4 cylinder Scotty's is already halfway into his conversion based on that Scotty's so we can't reverse the sale. We have checked/searched online for available 4 cylinder adaptors but, so far, have not found any. This leaves us with finding a machine shop equiped with a mill or a lathe large enough to fit both the adaptor and the 4 cylinder bellhousing. Once we find such a shop, we will have them enlarge the inner diameter to fit the 4 cylinder lip as well as drill new holes to match the 4 cylinder bolt pattern (fortunately, the Scotty's Adaptor has the "boss" locations for both 4 and 6 cylinder bolt patterns).

Speedbump #2: After working the math on where the engine will rest after being pushed forward 4 inches to accomodate the R380, we realized that the Chevy oil pan will interfere with the front axle. So, we have two options. First, push the transmission back. We are not in favor of this because that was one of the main reasons for choosing the R380--it would drop right into the existing mounts. So, by default, we have chosen the second option--raise the suspension. This means converting the galvanized chassis to military suspension. Most of this conversion involves bolt-on parts but we will have to change the front spring mounts for both front and rear leaf springs. Gord'n is looking into either fabricating those new mounts or ordering them from Richard's Chassis in England (www.richardschassis.co.uk). One other chassis modification will be installing a notch in the second cross member so the front prop shaft will have room to travel. This conversion will raise the 109 by 1.5 inches. Because it is already a top heavy vehicle and because the combination of the R380 and the 3.54 diffs will make it even easier to drive fast, we will also install the front and rear military sway bars.