Hi Ian, All....
I thought I had caused the problem when I had the little accident with the Gearbox during test fitting etc..
Seams not to be the case so I am somewhat relieved.
Phew!! Another one of those things one finds out as one goes along eh?
The exhaust problem I got round by some carefull heating and bending. I had the engine and box on the bench at the time though and just aimed the 'y' pipe where I wanted it. It is about an inch lower though. No problems with the speed bumps and it looks nice n neat so I am happy with it.
I would like a little time to test the mod I have done to the shift lever before I put up some pictures etc. But basically I tried the version published earlier (check the posts) by Victor? who did a complete write up on rebuilding the box and fitting it. Cant remember his name right now..Sorry. He recommended cutting off the 4 speed lever from its rubber mounted type boss and reversing it then clamping it onto the 5 speed 'stub' via a special made spacer tube. That we found did not work too well and it came slack. I got round the coming slack bit (Previous post) but found the lever twisted the 'stub'/ (the gear lever into the box) and made selecting the gears even more sticky feeling, and did not work at all well with the 4 speed rubber boot/ gaiter. So....another design was needed. Quickly... I cut the 4 spd lever from the rubber mounting bush assy. I turned up a collar which fits fully over the top of said ass'y, onto which I welded the lever at an angle to put the knob where I wanted it and grub screw fixed (x3 @ 120 Deg') the collar to the bush. This helped cure the problem with where the lever was placed in the rubber boot too, so I sorted two issues with 1 mod if you like. And it sure drives nice. It is just snicking the ratios into place like a good un...
The short lever though means a little more effort is needed to select (and deselect) the gears. Not a problem though. 1 - 4 are just the same as the 2000e box so far, and Graham Boulton says they will get even better when ran in.
I'm very pleased with the end result..
When I've a few more miles under its belt I will then modify my 5 speed lever to fit and return the prototype to Andrew King (thanks Andrew). I want to test run it for a bit before I burn my bridges. As of now I can still go with the 5 speed lever if I wish. Just don't want to have to fit a leather gaiter etc and the lever looks wrong I M H O.. Too long for 1 thing.
I will keep you all posted as normal.
Alex.
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