To build the bellhousing for the TDI I took two steel plates,drilled both to bolt up to the engine. On one I cut a circle slightly larger than the flywheel, the other I cut a hole just big enough for the trans. to fit into (5-spd geo tracker with alignment bushings on two bolts) I then threaded 7 inch pieces of ready rod(all-thread) into the 5 holes in the block. Next I slid the first plate onto the ready-rod over the flywheel, against the block. Then I cut a 12 inch pipe about 4.5 inches long and put it over the flywheel,sticking out from the engine. Then I slid the second plate onto the ready-rods and nutted them to sandwich the pipe between the two pipes all bolted up to the block. I then proceeded to weld the plates to the pipe/ring.
Many measurements were taken,many mistakes made, more than one plate discarded. After the thing had cooled I discovered, not to my surprise, that it had warped. I took it to a machine shop to have it surfaced to make both sides of the "bellhousing" parallel. It didn't take much. I brought it home and took the flywheel off the engine. I made a piece to bolt to the crank that stuck out about 8 inches, then bolted the bellhousing back up to the engine with the bracket piece sticking out the hole where the trans. goes. On the end of the bracket piece I attached an arm. On the arm I attached an adjustable pointer and adjusted it tight to the outside plate of the bellhousing. (this bracket piece,arm,pointer-scribe was all very crude and made very quickly out of scrap)
Then I just turned the crank to scribe a circle. I got some help to mark the bolt holes from this circle taking extra care on the two alignment holes.
I left a lot out like the starter,drilling trans. holes etc., but this is long enough.
What I've ended up with is a bellhousing that connects a 1.9 TDI to a geo 5-spd. using original TDI flywheel,pressure plate,and starter.
