SE50 dio gear swap

[turtle13]

does any one have any photos and directions showing how exactly to swap the dio gears into a SE50/NB50 based engine? im sure most of the aero-philes here on the board (including myself) feel that the most limiting factor of this engine is the lack of gears. sure there are the malossi's and the elusive 10:1's but thats a pretty big gap between the two. and if your engine falls between the two you either over rev your engine or get poor take off...
plus if we can compile a how-to, we can put it in the WIKI so all future aero and 87 elite owners can have the info available!

[mousewheels]

Chevyguyjay's long thread is full of info. http://www.hondaspree.net/phpBB3/viewto ... ilit=gears

Wheelman-111 has a info packed version too http://www.hondaspree.net/phpBB3/viewto ... ilit=gears

We'll compile the info for the 'wiki' over the slow winter months. If you find more info that should be included, please post links

[Trafficjamz]

I've done it.

It is easy.

Just use all the gears from a pre 98 af16e.

Then use a lathe to turn down the counter gear.

[turtle13]

I've done it.

It is easy.

Just use all the gears from a pre 98 af16e.

Then use a lathe to turn down the counter gear.

is this with the stock afo5e tranny cover? or with the af16e cover?

[Trafficjamz]

It does not matter what cover you use.
The double ball bearing af16e (pre 98) and the af05e covers are the same.

The difference in in the case, not the cover.

[eliteguy50]

The shaft needs cut down because the af05 case is shallower than the af16 case.

Edit: TJ beat me to it.

[turtle13]

ok so, you swap everything from clutch shaft to the axle, and then turn the countershaft to fit (in width and length). seriously, thats all it takes! why doesnt every one do this? if only there was some one on the board that was reliable to help members out with machine work... they could sell quite a few "swap kits" if one was put together already machined...

[turtle13]

granted i dont have an engine case in front of me to check, but could the case be machined to accept the dio trans as well? being the im going to be building the new engine from square one, this would not be any more work. or would it just be easier to trim and machine? how much exactly do you have to take off? or is it a simple, make the two match ordeal?

[eliteguy50]

That countershaft that you have to cut short comes with the secondary gear set so you have to do it each time you change ratios. I have thought about boring out the af05 case but have not had the time to take it to the shop for a test run yet. The countershaft is about 3mm too long on the case side.

The af05 and af16 cover have the bearing points all in the same place, but they are not identical as a whole.

Cost is a big reason why everyone doesn't just go out and get a swapped set. You shell out $100 for the dio conversion and you still haven't bought the aftermarket gears yet.

[Trafficjamz]

ok so, you swap everything from clutch shaft to the axle, and then turn the countershaft to fit (in width and length).

The width is the same......only the length has to be changed. I did mine with an angle grinder.

Getting your hands on the af16 gears is really the only challenge.

This swap works in reverse as well. (af05 stock gears fit in the af16 case with no mods.)

[Trafficjamz]

That countershaft that you have to cut short comes with the secondary gear set so you have to do it each time you change ratios. I have thought about boring out the af05 case but have not had the time to take it to the shop for a test run yet. The countershaft is about 3mm too long on the case side.

Boring the af05 case would work too. This way MUST be done by a machine shop.

[eliteguy50]

That countershaft that you have to cut short comes with the secondary gear set so you have to do it each time you change ratios. I have thought about boring out the af05 case but have not had the time to take it to the shop for a test run yet. The countershaft is about 3mm too long on the case side.

Boring the af05 case would work too. This way MUST be done by a machine shop.

Or by a friend who is an engineer

[eliteguy50]

... This swap works in reverse as well. (af05 stock gears fit in the af16 case with no mods.)

x2, swap in the 10.2 af05 gears for a bolt on upgrade with no press work.

[turtle13]

Ok I get it now. The picture makes it look like they are different diameters, but there not. Just an optical dilusion. Sweet! Now to scour ebay for the winter months for a gear set to start with and find somebody to machine my case.