I'm trying to figure out a way to add ~10 lbs to an OM616 flywheel. I was thinking that I could buy thick sheet metal and cut rings out of it to then weld/bolt together and weld/bolt to the FW. I could also find some really thick metal that I wouldn't need to cut -- although wouldn't that be more difficult to cut?

Also, if I cut up an OM616 FW for a ring to bolt on for the extra 10#s, what would I need to cut it with?

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"Senior Luna, your sense of humor is still loco... but we love it, anyway." -rickymay ____ "Your sense of humor is still loco... " -MBeige ____ "Señor Luna, your sense of humor is quite järjetön" -Delibes

1982 300SD -- 211k, Texas car, tranny issues ____ 1979 240D 4-speed 234k -- turbo and tuned IP, third world taxi hot rod

2 Samuel 12:13: "David said to Nathan, “I have sinned against the Lord.” And Nathan said to David, “The Lord also has put away your sin; you shall not die."

Talk to a machinist at a machine shop that turns flywheels.

Why not just weld two flywheels together?

I wish... but the FW has a significant lip, like this:

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"Senior Luna, your sense of humor is still loco... but we love it, anyway." -rickymay ____ "Your sense of humor is still loco... " -MBeige ____ "Señor Luna, your sense of humor is quite järjetön" -Delibes

1982 300SD -- 211k, Texas car, tranny issues ____ 1979 240D 4-speed 234k -- turbo and tuned IP, third world taxi hot rod

2 Samuel 12:13: "David said to Nathan, “I have sinned against the Lord.” And Nathan said to David, “The Lord also has put away your sin; you shall not die."

removing weight from flywheel would give you better performance.

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1999 w140, quit voting to old, and to old to fight, a god damned veteran, deutschland deutschland uber alles uber alles in der welt

I gotta ask, "why?"

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1982 300SD " Wotan" ..On the road as of Jan 8, 2007 with Historic Tags

LOL, yea why?

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Jim

Yeah,don't ruin a 616 flywheel.

steel isnt all that expensive, find a local steel yard to buy material. they will usually rough cut for you depending on the level of service they might supply, ranging from "**** you" to "how can i serve you".
i go to a great one in dartmouth mass, no restrictions on minimum purchase, and they will cut anything up for you

another option is buying scrap steel out of a scrap yard in the sizes you need.

methods of cutting for thick stuff you will need are torch, plasma cutter, 5 years with an angle grinder and 30 wheels, or take it somewhere and pay for waterjet or lasercut or something similar.

the flywheel is cast iron, so there are procedures to follow to weld it properly by heating it up ,but id skip that and bolt it.

if you really want to go to this trouble, i wouldnt destroy an increasingly rare stock flywheel. id buy a 4x4 sheet of 3/8ths or 1/4 inch steel and have a bunch of identical rings cut with bolt holes already by a place with laser or water cutters, then drill and tap a stock flywheel, and stack them as needed.

honestly though, lots of time, cost, trouble, and work for very diminishing returns. a 28lb flywheel is perfectly fine for a 617 assuming its been match balanced. half the time people are complaining about their flywheel in a conversion is because they didnt take the time to match balance flywheel and driven plate. a lighter flywheel will return better performance, but any weight flywheel will be a problem if the balance is off.

you go to all the trouble to add weight to a flywheel to improve smoothness, it still has to be balanced for a 616 and match balanced for a 617. my 617 with a 28lb flywheel was plenty smooth. i thought about doing this once too, but this activity might be close to looking for the sexiest dress for a donkey. whatever you do, you may not be impressed with the results, and in the end ruin a perfectly nice dress and piss off a fairly happy donkey.

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I assume you're wanting to convert a 617 auto to manual. Just use the 616 flywheel and avoid low rpm high loading conditions.

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Whoever said there's nothing more expensive than a cheap Mercedes never had a cheap Jaguar.

83 300D Turbo with manual conversion, early W126 vented front rotors and H4 headlights 401,xxx miles
08 Suzuki GSX-R600 M4 Slip-on 26,xxx miles
88 Jaguar XJS V12 94,xxx miles. Work in progress.
99 Mazda Miata 183,xxx miles.

I wouldn't treat that as a rule.

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68 280SL - 70 280SL - 70 300SEL 3.5 - 72 350SL - 72 280SEL 4.5 - 72 220 - 72 220D - 73 450SL - 84 230GE - 87 200TD - 90 190E 2.0 - 03 G500

Nissan GTR - Nissan Skyline GTS25T - Toyota GTFour - Rover Mini - Toyota Land Cruiser HJ60 - Cadillac Eldorado - BMW E30 - BMW 135i

Just buy a 617 flywheel??

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

Bolt on a harmonic balancer.

I think you've drank the peach parts coolaid jooseppi. For the 3 people who harp on the vibration issue, there are 15 telling you its not an issue when match balanced. Do the swap with the 240 flywheel. If it bothers you it takes an hour to drop the manual trans and you can pony up for a 300GD flywheel.

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68 280SL - 70 280SL - 70 300SEL 3.5 - 72 350SL - 72 280SEL 4.5 - 72 220 - 72 220D - 73 450SL - 84 230GE - 87 200TD - 90 190E 2.0 - 03 G500

Nissan GTR - Nissan Skyline GTS25T - Toyota GTFour - Rover Mini - Toyota Land Cruiser HJ60 - Cadillac Eldorado - BMW E30 - BMW 135i

Some people say that the OM616 FW (10 #s lighter than the OM617 FW) causes vibration issues on the OM617, especially at low RPMs. Others say it doesn't, or that it only does so at lower RPMs.
Thanks a lot for all that, it makes sense.
Does that mean keeping the revs above 2000 RPM at all times or only when climbing hills/accelerating? I like riding in the low revs .
The only one I'm aware of in the US right now panZZer's, and his eBay auction looks hairy as far as the shipping goes. Plus, I think he hates my guts.
Yeah, I think what you and JB3 say does make sense in the end.

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"Senior Luna, your sense of humor is still loco... but we love it, anyway." -rickymay ____ "Your sense of humor is still loco... " -MBeige ____ "Señor Luna, your sense of humor is quite järjetön" -Delibes

1982 300SD -- 211k, Texas car, tranny issues ____ 1979 240D 4-speed 234k -- turbo and tuned IP, third world taxi hot rod

2 Samuel 12:13: "David said to Nathan, “I have sinned against the Lord.” And Nathan said to David, “The Lord also has put away your sin; you shall not die."

I ask because the replacement transmission I installed in 300SD is not going in any gear right now, and unless it's the front pump or something to do with the valve body that I put together wrong, I'll want to spend my time swapping a manual instead of diagnosing and fixing an automatic that I don't want in there forever anyway.

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"Senior Luna, your sense of humor is still loco... but we love it, anyway." -rickymay ____ "Your sense of humor is still loco... " -MBeige ____ "Señor Luna, your sense of humor is quite järjetön" -Delibes

1982 300SD -- 211k, Texas car, tranny issues ____ 1979 240D 4-speed 234k -- turbo and tuned IP, third world taxi hot rod

2 Samuel 12:13: "David said to Nathan, “I have sinned against the Lord.” And Nathan said to David, “The Lord also has put away your sin; you shall not die."