why can't i put a 4 spd box in a early v90?

[tzsteve]

a lot of work, i like the ideas and solutions.

how did you keep the alignment of the two parts of the axle while welding?

ill have another read of the post and see if i missed that detail

[guygrrr]

Dec 15, 2018 17:56:25 GMT tzsteve said:

a lot of work, i like the ideas and solutions.

how did you keep the alignment of the two parts of the axle while welding?

ill have another read of the post and see if i missed that detail

Thank you tzsteve. Fortunately the axle wasn't that badly damaged. The welding was really only to add material to machine from.

[tzsteve]

got it mate

[guygrrr]

A few weeks before Christmas I received this little gem from SIP.



It’s DRT, 69/27 straight cut and hopefully give some flexibility to the gearing. I was initially looking at getting a primary rebuild kit for one of the clutch baskets I have here but than I noticed that I would be able to easily disassemble this one. Sold!

I commenced to pull it apart with the intention of making it a bit shorter. Heat, in moderation, is your friend here because of course the screws are loctited in. Which makes perfect sense and only dawned on me after I did a number on one of the little socket screws.





I thought I would take it easy on my self and just cut the end off with an abrasive wheel. This was good in theory, but I didn't have as much control as I thought I might and ended up probably taking off half a mm too much.









I figured that .5mm wouldn't be a problem but I had a devil of a time trying to get the kickstarter to play nice with the shortened DRT basket. The kick pinion wasn't being properly held in place by the quadrant and was constantly engaging the xmas tree. Fearing the worse, and suspecting that I just ruined a brand new part, I left well enough alone and went off to the corner to think about what I had just done.

[tzsteve]

DRT do make some nice stuff.

re the kick start;

i guess you do have the spring and the dished washer in place

and that the kick quadrant spring is correctly fitted

[guygrrr]

I haven’t been able to get to this thing for a second but as it turns out I did have the kicker pinion spring and washer assembled properly but something obviously wasn’t right. I pulled it apart, though, checked everything out and reassembled it and lo, all is well and everything works. Beats me.

Fwiw, this was the actual damage to the axle. Nothing major at all, some of the corners got knocked off the upper edge of the snapring groove. Probably would have functioned just fine but I felt better blobbing some weld on there.



I won’t consider this a success until I get the clutch in and I’m fresh out of that little woodruff key for the clutch pack, so I’ll have to wait a bit. The consideration with the clutch is that with all the moving of things around on the gearbox side, the top plate of the clutch pack could potentially sit proud of the basket. I eye balled it and think I may be ok but that, my friends, is still an assumption.

Fingers crossed I’ll be able to make some time next week to mess with it.

In the meantime, does anyone have a clue what these shims may be for? They came with the DRT clutch basket and I can’t see any shafts that they are a close enough fit to, to figure out where they’re intended to go. It’s odd because they are all a pretty sloppy fit on the various things that they would be closest to fitting.

[tzsteve]

they aint standard items on a smallie.
i think you will find they go with different small clusters such as the runner etc
the 3 small ones and the big one next to them look they are for spacing the rear brake back plate when fitting a spacer on the clutch cover