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[Shackeng]

I'm currently at an impasse with this project. I am unable to find any 6 pin plug connectors that will fit the 22mm hole in my new box. These are all sold, according to suppliers of harnesses (including one in the US), as type specific items, with no information available as to diameter of fitment. I have also been unable to find a manufacturer of the plugs themselves, who in any case would probably only deal with car producers or spares suppliers.

[Marks DTM Calib]

Get the step drill out.

[Shackeng]

That's the road I am considering, bearing in mind that the sumps are not pressurised to any great degree, so it merely has to be leak proof.

[Diamond Black Geezer]

At what stage is this impasse? Just wondering, because you've still the potential to source a good, used Omega AR35; certainly you've put plenty of hours into this, which (in theory of course) you were hoping to saving yourself, by buying the brand new box.

I'm not saying 'cut your losses' as such, because you've still got a fabulous box, which would be a nice easy fit in any straight-six pre-Omega B product of Russelsheim. I suppose what I'm saying is I (and I'm sure plenty of others) don't want to see you losing precious hours of life buggering around with this box and causing more aggro than its worth, when there must be actual Omega boxes available which can be done with ease in a day, or relax and spend 2 days and do the sonax washer mod too. 

The above is intended positively, and in the best way, in no way being critical, just trying to get the best resolution for you   

[Shackeng]

At what stage is this impasse? Just wondering, because you've still the potential to source a good, used Omega AR35; certainly you've put plenty of hours into this, which (in theory of course) you were hoping to saving yourself, by buying the brand new box.

I'm not saying 'cut your losses' as such, because you've still got a fabulous box, which would be a nice easy fit in any straight-six pre-Omega B product of Russelsheim. I suppose what I'm saying is I (and I'm sure plenty of others) don't want to see you losing precious hours of life buggering around with this box and causing more aggro than its worth, when there must be actual Omega boxes available which can be done with ease in a day, or relax and spend 2 days and do the sonax washer mod too. 

The above is intended positively, and in the best way, in no way being critical, just trying to get the best resolution for you   

None taken, however the actual time spent is not significant, it probably appears more due to my multiple posts. Remember, I have a spare car to use, plus SWMBO's, so there is no great rush, and I have a large double garage/workshop to play in. Also, as I hope to keep the TD Estate for as long as possible, I would prefer to fit a brand new gearbox. The plan is, once this is fitted, to refurbish the old box as a spare for either car. If it doesn't work, then the refurbished box will go straight back in.

[Diamond Black Geezer]

That's a good plan, and if you're in for the 'long haul' (as I am too so fully empathise with what youre saying) then an entire spare box sounds very fair. Ive got some scrubground round the back of our flat, which is mine, I pay rent on it, and is frequently used/abused/block me in or out by every other bugger in the entire of N E Lincs, apparently! haha, so if i had a double garage then I'd no doubt be doing similar to yourself. SO long as it's all being a positive experience, and you're still heading in the right direction, that's fine. Keep it up. Wish I could offer any kind of technical help, but this is beyond me. I once swapped an AR25 for an AR35 with a mate on his car, but that was Omega-to-Omega. Keep it up is all I can say. Also keep the old bits so one day you can sell it to a Senator/Carlton owner!   

[Shackeng]

That's a good plan, and if you're in for the 'long haul' (as I am too so fully empathise with what youre saying) then an entire spare box sounds very fair. Ive got some scrubground round the back of our flat, which is mine, I pay rent on it, and is frequently used/abused/block me in or out by every other bugger in the entire of N E Lincs, apparently! haha, so if i had a double garage then I'd no doubt be doing similar to yourself. SO long as it's all being a positive experience, and you're still heading in the right direction, that's fine. Keep it up. Wish I could offer any kind of technical help, but this is beyond me. I once swapped an AR25 for an AR35 with a mate on his car, but that was Omega-to-Omega. Keep it up is all I can say. Also keep the old bits so one day you can sell it to a Senator/Carlton owner!   

There is yet another option, which is to swap the new internals into the AR25 case, however, as my knowledge of auto transmissions could be scribed on the head of a pin, I would leave such a move to an expert. 

[Diamond Black Geezer]

Agreed I saw an AR35 internals once. Saw them clunk out of alignment. Bit specialist to reassemble. Best avoided 

[Shackeng]

Well, with the use of a step drill, I have enlarged the hole to 26mm successfully. I now need to remove another 1mm to insert the plug.
Years ago I had the ideal drill mounted tool for this which had 3 small grindstones 2 or 3 mil square, and an inch or two long, mounted horizontally along the mounting spindle, they then expanded under centrifugal force as the drill was started. I used it for dressing the internal bore of pitted master cylinders in the days when repair seal kits were available, and it worked very well. Does anyone know if such tools are still available? If not, any recommendations for a suitable drill mounted tool to dress the bore out, it is about 1" deep. Please don't suggest a round file, I've already spent 2 hours with one, and made no discernible impression.

Ah I've tracked it down, its called a brake cylinder hone.

[Marks DTM Calib]

Yes readily available:

http://www.ebay.co.uk/itm/1x-Brake-Cylinder-Hone-For-13-64-mm-Wheel-Tyre-Accessories-/191412923671?hash=item2c91196d17:g:e44AAOSwP~tW4pPw

[Shackeng]

Yes readily available:

http://www.ebay.co.uk/itm/1x-Brake-Cylinder-Hone-For-13-64-mm-Wheel-Tyre-Accessories-/191412923671?hash=item2c91196d17:g:e44AAOSwP~tW4pPw

Ordered one last night.
http://www.ebay.co.uk/itm/162103337419

[Mr Gav]

Keep up the good work Chris, I`m looking forward to seeing it in the car 

[Shackeng]

Well, I got  the brake hone this morning, which promptly sheared its thread as soon as I switched it on in use!  I found a nut to screw the arms back on with, and then the stones wore out within 5 mins of honing! Needless to say I am not impressed. However, it took it out sufficiently to allow me, with judicious use of a dremel, and after some technical adjustments to the plug itself , to fit the required electrical plug. So the gearbox is now fitted with the Omega electrical harnesses, and having checked the resistance of each thermistor, the new box original is 18.7KΩ, and the Omega thermistor is 17.7KΩ, which is close enough for Government work.
The next job is to actually fit the gearbox, and I approach this with trepidation, as JamesV6CDX did the majority of the last one. However, Joff has lent me a gearbox jack, which should make life easier.
Watch this space.
PS, I am going to try to fit it with the filler tube attached, having bought the Senny extension tube Aaron linked to (thanks Aaron), as looking at the space down the side of the TD engine, I think it may be doable, even if the tube requires some technical remodelling.

[Mr Gav]

Excellent, I think the extension tube should fit ok with a little, if any bodging   

[Doctor Gollum]

A little perseverance goes a long way