Making Billet Aluminum Transmission Adapters - E55 Manual Swap Part 1

[@ahamedkhan232]

engraving all the info on the plates themselves is so big brain.

[@kiwihame]

It's the little things. =D

[@eformance]

I have a couple suggestions about the plates (when I had a shop, I machined > 75 different plates for different makes for a customer): You have a good start with the 2 hold-down bolts in the center. I also recommend that you drill hold-down holes for the drops in a pre-cycle, then bolt down the drops. Then machine the dowel pins and outside profiles. Bolt the plate down by several of the holes, then do the inside profiling. This constrains all of the pieces and prevents wasting carbide endmills when the drops kick out. You can just put optional stops for each of the pauses. I suggest machining the dowel pin patterns into the sub-plate so you can flip the plate over on the dowels and have it exactly centered for the 2nd op. You can follow this pattern for both pieces. I would suggest a live tooled lathe as your next machinery purchase :-). When I did the hubs, I did all turning on a lathe (did both manual and later CNC), then 2nd op the holes and tapping on a Mill. I think it will be tough to maintain very tight tolerances doing the hub machining in the mill on a cheap 3 jaw chuck. Obviously the 1st op doesn't matter, but accurately chucking the 2nd op can be challenging. You might consider machining a fixture to accurately locate and support the 2nd op of the hub, then you'll know center and the face will be perpendicular to the spindle.

[@Gizawar]

Maybe now Tavarish will manual swap his SL55

[@AbdulrahmanHadid]

Same thought

[@georgobergfell]

Haha, I thought the same as well

[@lukasmeyer1992]

I am already waiting for this moment for so long. I dont watch his videos anymore, just check every now and then if the SL is already swapped.

[@gianfrancoa]

Hahaj I was going to write the same. The only difference is that Tavarish has no idea on how to do it, ad this guys it does. Tavarish had has thi project on the shelf for 3 years.

[@gianfrancoa]

That's the difference between doers and talkers

[@vijayvjn6874]

this was very well documented as always, can't wait for the next one

[@longboarderebright]

its amazing to of found your channel with the orange car you built years ago because i was looking for diy mini race cars! and then i got to see the track car get built, now your in a shop! thanks for the inspiration keep fabbing!

[@eformance]

For through holes I recommend you get some spiral point taps, for blind I recommend you get some "CNC" or Spiral flute taps. That plain tap is the most likely to get clogged and wipe out the threads or break.

[@davidfrom313]

Man you are truly a great person, you develop a much wanted part and then you don't sell it until you can offer it at the best price. Keep it up man. Thanks!

[@adamhamilton8242]

This is amazing work! The amount of thought put into this project is astonishing. I eventually want a W211 E63 estate which I’m planning on manual-swapping

[@nickgeorgiakakis7249]

Excellent! You're onto a winner here. Really like the engraving of the specs on the adaptors.

[@FixItRyan]

Imagine driving one of those into the Mercedes dealership!

[@finlay230]

Ryan N priceless !😁

[@SergejKolmogorov]

I have some manufacturing advise for you. You transport the whole power over the bolts that hold small adapters inside the transmission. If you make more edges on adapters themselves, that they fit in each other, those adapters would transport the power also and make the life of bolts easyer.

[@quickvictor]

Makes sense 👍

[@jdantigua1999]

Tavarish youtuber out of Florida will buy one for sure. Great video and you are making technology work for us simple mercedes pesants.

[@slvr1.618]

You just made an engineers wet dream a reality!and Karen is a most welcomed addition to channel,keep up the great work.

[@akenthusiast101]

I have been watching your channel now since the beginning and i am amazed at the knowledge and technical info you possess. Keep them coming.

[@longboarderebright]

i like how you turned the drive shaft instead of from the engine side it looks great!

[@kiwihame]

LOVE your work! Just awesome. And the little 'attention to detail' touches are just the icing in the cake. Deeply impressive. Now off to find an E/SL55.

[@olegloginov6328]

Consider one kit sold! As far as electronics, I believe there is an option for coding a manual transmission. It is located under Developer mode for DME in factory DAS software.

[@BmwpetroldoorshoppingcarNordsc]

Cool if this is true!!

[@autospeed]

@@BmwpetroldoorshoppingcarNordsc I wouldn't be surprised, and I'm sure it's true. Merc offered manual transmissions on a lot of these cars for the EU market for many years. All of the Netherlands has Merc E-Class' as taxis.

[@BmwpetroldoorshoppingcarNordsc]

autospeed True, if I did this to my car I would want to use the standard factory engine management/mapping.

[@chr1ssss]

Other m113 manual swaps I’ve seen just leave the existing shifter in park so that is an option too.

[@srb2az141]

Just use a crossfire trans m113/112 are the same bell housing

[@grzegorzkolbrecki8344]

Just perfect! Perfect project, perfect machine and perfect operator, good job Karen (and the talking guy)! I like the final touches, better than OEM. I'm almost sad that I don't have an automatic MB to convert ;)

[@nissansfinest3245]

This a great project of interest for me. Every since I started manual swapping my Charger SRT8, more and more people are popping up doing manual swaps on auto only cars. Im lookin forward to this finished product. I also think that there should be a gathering for us that are doing these swaps.

[@sevenpaulperalta929]

This is engineer level work, well done!

[@MrSnowford]

Haven't been this excited since I got my CLS55. A manual swap has been a dream of mine someday.......now it looks like it may come true. Can't wait to see ho things progress.

[@gianfrancoa]

That CNC is impressive and even more impressive is the programming skills.

[@martinprehjan9944]

I myself have been looking into this for a M-119 motor for my coupe! ...but ended up converting the NAG1/722.6 to a paddle shit setup using an arduino! Hell...I'd even consider swapping in a M-113K just to be able to have a CD-009 backing it, since I would think you probably would not be willing to make one for the M-119!!! I guess I need to get intouch with you guys to see if you are willing to make one for me!!! ...that would be awesome! Hell why not make one for the M-120 motor, just imagine a 6 speed manual for the v12! I would love to do one myself, it will be smooth and powerful! wow what a combination! Keep up the great work, you made a lifetime subscriber out of me, now if i can only become a customer too! On a side note, I can count at least half a dozen customers that have asked me for just such a conversion in my shop! If only everything existed so I could just say yes and start ordering swap kits! I wonder how hard it will be to make different transmission side and flywheel couplers for say a Tremec 6 speed and a ZF transmission! ...just food for thought guys!!! ...and I guess gal!!! As for the female CNC'ist...brains and looks, now she is a winner in my book!

[@Usmanthemecano]

Channel is grossly underperforming... Great content

[@randallmason9687]

Spread the word!

[@reidcotten2720]

You inspired me a year ago to build this same setup in my 99 clk430. Made my adapters just a little different and had the simpler bolt pattern to work with. I’d love to send you pictures and video if your interested. I’ve followed every step and wound up with an adapter set that I’ve drifted with for over a year now on the same clutch

[@187g]

Nooo waaaay !! Finally ! a manual swapped mercedes 😍 get ready to swap a 6.3L s63 mercedes for me 😍😍

[@1uzfe]

I have to do this to my 1uzfe. Its exciting because I’m studying everything that you showed in this video 😁 I cant wait to implement my ideas on my car

[@Moolaz]

Great job. These look like they are proper quality.

[@papapetad]

You may also think about shifter surround to integrate it neatly with the interior + driveshaft and as you said, electronics, to make it a full kit if desired. Working these details out can be great value added for you with customers who wouldn't want to deal with it.

[@turbomar6667]

Wishing you great success with your new business👍🇨🇦

[@Doan84]

awesome that you engraved all the info on the parts themselves!

[@seansswaps3804]

I'm glad to see you doing this swap. I tried manual swapping a C32 4 years ago and got stuck at the ECU. I got as far as getting the engine to start and run without the transmission or shifter modules. Unfortunately the engine's power was severely reduced. None of the US based tuners were willing to help me with the swap either. I wish you better luck! Mercedes has a flex-plate part number change at engine #60 046180. I ran into this on an M112 and I think it changed in 2004. Not sure if the 113k's were later though.

[@deepredkadett]

Why haven’t I read this 1month earlier? Just swapped my Slk32 to manual and have exactly the same problem :-( Was able to code it to manual, so could start without shifter and tcu but absolutely no Power :-( :-(

[@trentdawg2832]

Dude, you are an automotive genius, I need one of these for my cls550

[@n.shiina8798]

nice work. engraving torque spec is such a nice touch

[@tomb375]

Amazing Job! Love that CNC machine. I would love a better designed Transmission Pan For the 722.9. Thank you hopefully you see this. Your an excellent designer engineer! Love all your videos and congratulations on your success, God Bless!

[@BrianCrofoot]

Very interested in the kit. Can’t wait to see the build go in the car as I have an ‘05 E55 that I want to manual swap! Edit: I ordered my kit like 2-3 weeks ago! So stoked!!!

[@greddy3949]

Cant wait to see the vid for the M156 Manual trans swap🙌🏻👍🏼

[@markamd1]

HOW doeas this Cahnnel not have 1million subscribers??!! WOW!!! Amazing work brother, keep it up! Hello from Calgary! :)

[@collinjohnson7723]

The only thing that makes me want to sell my E55 is the trans. The auto isn’t terrible but I miss 3 pedals. Can’t wait for the kit to be available!

[@csc_1]

In Germany we have W211 with manual Transmission from stock. 4 Cylinder engines. If you need a hanging MERC clutch pedal. Also the brake pedal is smaller in width.

[@LyonScapeStudios]

Awesome work, loving the builds, I really hope you turn the feeds and speeds up on that mill! Let er eat!

[@Gatsu3D2A]

I need this! I spread the word on the amg groups. Lots of interest in this.

[@Marcos_P82]

Would adding that much weight to the back of the engine would damage the rear crank bearing, I just thought of that when I saw how far the cd09 flywheel and clutch, looks amazing BTW

[@Emangia]

Damn, that looks pretty professional, excellent job!

[@KarelBeelaertsvanBlokland]

Love your work and attention for detail! Well done. Keep on the good AMG work!

[@davidmitchell5638]

Doing what tavarish promised us but didn't! Following this wholeheartedly.

[@artrecogniseart]

Beautiful just beautiful. I look forward to the day I'm able to make my own parts. Lovely content.

[@vitor900000]

Yo! When are you going to get back on the E55 ASL project? Its almost 6 months since the last time you did any progress on it D: I miss it...

[@regee90]

Cant wait to buy this kit. Much love from the UK.

[@hydorah]

Bloody brilliant mate! Hats off to you!

[@hydorah]

I found this for you, maybe it will help :-) mbworld.org/forums/clk-class-w209/750479-2004-clk320-manual-transmission-swap.html

[@gafrers]

Wonderful job, great attention to details and precision. Love the engraved torque specs

[@lukep6017]

Great job for creating this video. Excellent job

[@bl00dh4nd5]

Superb craftsmanship, keep it up

[@valentinolim7144]

This is the only Karen that the internet will approve. The Karen that talks technical and operates CNC. We need more Karens like you!

[@iceeice1234]

Can you please do a super in depth video of how your able to get the electronics to work.

[@dave7856]

Hi Excellent video well done both of you and some very good positive comments, as a confidence check - a run out check on the face of the flywheel clutch surface to check for any misalignment and edge of flywheel for up and down would be my recommendation. Would it not be best to make your crankshaft adaptor from steel?

[@kk.7177]

So cool to see you two working together ;)

[@endeavour2127]

Great content, looking forward to part 2!!!

[@Dr-Asim]

Will the back of the crank be able to support the extra weight of having a heavy flywheel vs flex plate, and on top of that it's spaced further out, which also puts even more stress on the end of the crank. Really nice job anyways. This is how it should be done. Keep it up 👍🏾

[@johnparrish9215]

A pretty Lady with her own CNC machine, she would never be lonely around here that's for sure.

[@dzmitryulasau878]

As for the bolt crankshaft pattern it simple, engines with serial number update 046179 are using older bolt pattern (bolts are evenly spaced) and starting from 046180 - newer bolt pattern.

[@NorVack]

Thank you for this, definitely something ill be doing in the future to my s55 !

[@cecilcompagnon595]

Beautiful work, skillfully done. Awesome!

[@salvadorebertolone]

i would have them roughed in on a water jet. get a full 5x12 sheet cut at once and then you dont have to worry about drops jamming in your cnc and it only needs to do finish drilling, counterboring, profiling and surfacing. it would make it a 3-4 minute part on your cnc. or if you are trying to avoid outsourcing any work you can leave tabs or an .010-.015" skin in the slots that you can cut with knife to remove the drops.

[@autojando7223]

Only time you forgot to formally introduce a new face to the channel is when you had a lady on it😂😀

[@xfmotorsports]

Mentioned her in a previous video. She does all the office work and some of the design and cnc stuff

[@autojando7223]

@@xfmotorsports Oopsss! I prolly missed the video. Keep the content coming, i'm loving the way you keep transforming channel from DIYer to a professional auto+machine shop with unimaginable prospects. Really wish i could be your intern bro.

[@BOOYAGA]

@@xfmotorsports you got a company email address? Have an idea I'll send you, just don't want to share it publicly 😜

[@mohitkr.chaudhary4005]

@@karenmdesigns I had once sent an email earlier regarding a question of A Arms setup , but still have not received any response yet . If you dont have the specific answer to it or something, that too is fine with me, but atleast you could have informed about the same.

[@mohitkr.chaudhary4005]

@@karenmdesigns Okay , no problem. Can you pls confirm the proper email address to which I will send the mail. The one link you provided above in the comments is just for text messages. I also had some images attached in my original mail, which I can't attach there.

[@MikeMcDonoughUS]

Great looking work! Makes me consider a Mercedes based project.

[@serbancordis3416]

Electronics are very easy. Find a SDS (cracked version) and i believe there is a setting somewhere in the ECU section where you can select between manual and auto transmission.

[@winkertune]

Very very cool! can't wait to see this happen and we see some manual 211 e55s. I recently manual swapped my w210 e55 but I used a crossfire transmission, I wonder how much stronger this trans is?

[@Realtime1501]

This has been pushed to over 1400hp in the Nissan world using a stock transmission,so I don't think the Mercedes engine will be a problem

[@nfarnell1]

One Question, will the flex plate be stiff enough to keep the ring gear aligned with the starter pinion? Looks like beautiful product, well done.

[@diyaarustom9940]

Great job dear, hopefully it will be later an adaptor kit for the M275 engine. Best of luck.

[@guerinwoodgate]

There seems to be a high amount of mass being shifted away from the crankshaft flange. I am curious if there have been any calculations to simulate crankshaft fatigue or failure?

[@xfmotorsports]

There's actually a lot more force on the other side of the crankshaft when it's pulling supercharger belt with over 200kg of tension. An 18kg clutch and flywheel doesn't really do much. Been running this setup reliably in my racecar for about a year

[@DarkstarNovembr]

@@xfmotorsports How do you find the forces to simulate on the adaptor flanges? Did you just simulate a maximum inertial force of the mass of the transmission? How extensive was it? I'm just interested in how someone might go about it, if all the information isn't given

[@TheKing-pr4ef]

Great video man. Is it possible to do the same thing with w211 E350

[@savostanivukovic9801]

Absolutely awesome as usual! Well done sir! Would it be possible to provide flange bot style on 350Z transmission side?

[@jaredp4478]

I would love to see some M120 stuff!

[@hamedelrayyes]

That’s a dream coming true, great job, can you tell me what program you used for loads simulation?

[@rlew12]

Awesome kit and development! Are you planning to do a transmission mount adapter or replacement cross-memeber/shifter linkage?

[@epapa737]

I need this can't wait till it's released

[@Daemione]

Can't wait for part 2! Also can't wait for my stock C55 transmission to die so I have an excuse to make the swap. :p

[@skullofserpent5727]

Was it impossible to create 1 daptor only? So it could bolt on to an engine and the gearbox would've bolted on that adaptor. A bit thick ring , so it could have enough depth threads for gearbox bolts?

[@biomecaman3514]

new sub love the content, who is your go to for suspension geometry

[@Jeffball610]

I'm sure you've already solved this, but what do you plan to do about the shifter position? The CD009 is already pretty long, and adding two adapter plates is pushing it back even further. You also mentioned making sure the electronics can accept a manual transmission. That would be another major concern if this isn't going into a "race car". All the CAN systems in some of these cars makes it difficult to modify sometimes.

[@RealElwood1]

Very cool, what CAD/CAE software do you use?

[@derrickmartinjr6871]

Did you 3D scan the bellhousings to design the adapters in CAD, or did you just measure them by hand?

[@sarahdell4042]

I smell E55 prices on the rise now 😂

They have been going up, the last couple of years.

[@alcantarainterior8078]

Yep.. The time to buy em is now

[@alcantarainterior8078]

Btw the cheapest I have seen them is not less than 10,500

[@kiml85]

Interested in seeming how much electronics work it needs. I love my E55 and the only thing I wish was for it to be a manual.

[@nobhk]

Sound good for me as a Japanese.I can get the trans very easily.Also I am very interested in how to convert the ECU.I wanna try it on my c32.

[@kwbalance108]

SUBBED! Love this idea!

[@fm8453]

What strategy did you use to get all the measurements of the Mercedes and 350Z sides so accurate?

[@toddtempleton9321]

keep up the good work buddy !!!,!!!

[@kopiwerks]

May have missed it but will you be making adapters for other engines too? e.g. 2JZ to BMW transmission.

[@thedr4549]

How are you dealing with starter motor engagement with the new flywheel?

[@ludat5951]

Hey man, like your videos, well done ! I would love to manual swapCLS55 AMG, do you know if your adapters can work on CLS ? I appreciate your input .

[@bommaboy2789]

Not sure how many people would be interested, but it would be pretty cool to see the design process for parts like these, do you do any FEA?

[@georgeowen2083]

Nothing hotter than a women that likes to work on cars, but add the fact that she is a CNC Machinist makes her even more awesome.

[@suddendilemma5137]

Yes yes more of this yes!👏🏼👏🏼

[@Uninfluenceable]

just curious, in europe the W211 came with the 6 speed on the E270 CDI, which should have the same bolt pattern as the M112. Why not just use the complete transmission and pedal box from that car? Programming would be an issue regardless, but at least the mechanicals would be a bit more straight forward and "cleaner". I get that the nissan transmission has better support from the aftermarket, but this isn't going to be a racecar, is it? If it was a daily driver, I'd much rather have an OEM install than a hacked up center console and trans tunnel.

[@morkovija]

the background piano soundtrack at 18:40 is amazing, any chance for ID?

[@bigbird2100]

Great video 👍 could you use the probe to CCM each part and gather the data .

[@cuper1monta496]

Very nice quality! I would add though to not use a bushing for the pilot shaft. instead use a ball bearing design still cheap enough in price.. your job all in all though

[@Backyard_hunting]

Yes please thank you very much ! Email gone through 🙏🏼😬🥳 champion !