Well.. the chassis will need to be cut. I tried a oxy torch, it just made a mess. I am talking to a company that will cut the rail and reinforce it, and it will be engineered legally.

The area needed to be cut is 5 inches in length and 1.5 inches in height. I have just sent photos to them, fingers crossed..

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http://www.cardomain.com/ride/2541897

Damn..............well in order to answer the question now............no other box will fit without major modification.

Let us know how you get on.

if ur going to the trouble of cutting the rail. why not just fit a vr4 box in it anyways?

see how we go, this might cost a bit, and i already have the km206

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http://www.cardomain.com/ride/2541897

They said they will be able to do it. It is booked in for the 30 July, can't wait!

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http://www.cardomain.com/ride/2541897

expensive?

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Cordia owner again in 1 day....

i know u allready have the gearbox, but if ur going to all the trouble of cutting the rail and paying somebody to do it, i would personally cut my losses and do the vr4 box, i think u can pick one up for around 450 bucks.
just my opinion. but any box box is better then the std cordia box,
good luck anyways

not sure how much it is going to cost. He said he'll have the car for about a week, and that he doesn't know how much it will cost. He will charge by the hour... I made the cut in the rail yesterday and fitted the gearbox, perfect clearance! I'm spending today trial fitting the equal length shafts and cleaning up the cut in the rail.

Hey wizard, heard your selling your cordia, sad to see mate... Yeah i definitely want a vr4 box with locker, but one in good nick.. probably closer to $1000. i might go see SSS automotive to get a price. i still want to get the FP 68hta turbo..

And i've got rego coming up and the mortgage as well as many other things...

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http://www.cardomain.com/ride/2541897

I reckon it would be, A Few hundred for the mod to rail, then a $800-$1200 for the engineer cert (cover Rail and firewall) plus the price of the gear box, Shifter and so on.
My Guesstimate for full completion would be no change from $2500

Do you have any pics Newy?

i'll put some pics up later today or tomorrow. The cordia shafts fit perfectly, but the equal length shaft will need the same modifications Bitza has done to the sump and intermediate bracket to be able to fit.. Purchased a new power steering pump yesterday and did the wheel bearings on the front end, but the hub is worn out. I've never seen that before.

I'm going to try fitting the shifter cables today, try and get some photos of that too.

Oh, i'll try to keep a tally of the price just in case anyone else is interested in doing this. So far i've spent $350 on the gearbox, $50 on a shortened clutch hydraulic line and $20 on the Nimbus mount.

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http://www.cardomain.com/ride/2541897

Oh how very nice.

Can't wait to see some pics.

ok, i have not done much on the gearbox in the last few days but here is where i am at.

photos of the cut in the chassis, still needs a bit of a clean up.





gear shifter is mounted but i'll probably make up a proper adapter plate and modify the shifter because it is offset, it came out of a vr4..





and where i have painted a white box on the firewall is where i think i will be putting the shifter cables. They cant go any higher on the wall because of the heater box, and it lines up well there.



Off the topic.. i had to replace the passenger hub because it was worn out and ended up getting HG Galant hubs for it. My AC slotted and dimpled DBA discs will be up for sale, they are pretty much brand new..

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http://www.cardomain.com/ride/2541897

Newy,
How did you mount the shifter to the floor?

Did you just use the existing cover (with the bolts) and did you plate the hole in the floor?

What about the cables..........are they the right length?

Great to see the progress...........can't wait to do mine now.

i cut the old adapter plate up to fit which you can see in the close up photo of the shifter fitted, there are only 3 bolts fitted. i still need to make a proper adapter plate for the shifter which will fill the hole..

tomorrow will hopefully be productive, i have done the pilot hole in the firewall this evening. tomorrow i plan to finish the hole in the firewall, clean up the chassis, trial fit the cables and modify the shifter. see how we go..

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http://www.cardomain.com/ride/2541897

Nice.............this will be great when finished.............love your work!

the vr4 cables are roughly 15cm too long.. Maybe the cables from a cc coupe... Off to the wreckers again.

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http://www.cardomain.com/ride/2541897

That is a good question. Why do you think that a km206 is stronger than a km164 which is designed for a turbo engine?

The KM164 & 165 were also used in the RE colt model which had a 1600cc or an 1800cc Non turbo engine.

So technically it wasn't just designed for the Cordia being "turbo".

The KM164 was also used in the very early TM magna's behind a 2.6.

Are you sure the km164 is in a RE Colt? The only other car that I know that uses a km164 besides the Cordia is a TM Magna and that has a much larger engine of course.

The turbo and non turbo Cordia's use a different box. Most non turbos use a km162. The km164 uses tapered roller bearings which stand up to more power/torque, whereas the km162 and km206 don't.

Even if you are right and a RE Colt uses the same box, my question is still valid. An f5m33 would be a much better choice as it is designed to handle more torque and power.