My Gearbox Rebuild
Posted: Tue Aug 06, 2019 12:25 pm
A few months ago I was out driving my S2 Elan when I was greeted with a god awful crunching noise and a lack of drive in the first 3 gears.
I managed to limp the car back to the garage in 4th gear (was a short distance away).
It turned out of be a pretty terminal gearbox failure with the input shaft having lost all its teeth.
https://www.dropbox.com/s/8oxfc6unzmefl ... 3.jpg?dl=0
https://www.dropbox.com/s/f4lri16n98dow ... 7.jpg?dl=0
Like any good repair this is where my gearbox rebuild progressed to
https://www.dropbox.com/s/koak0swnx2pii ... 9.jpg?dl=0
https://www.dropbox.com/s/1q2be4e6wmxgz ... 0.jpg?dl=0
Nothing like a bit of scope creep! The thought process was while I've got the engine and gearbox out I should paint the engine bay..... and while I'm painting the engine bay I should paint the rest of the car.
I was lucky enough to have access to Richard Mann who helped with the fiberglass repairs. He also provided the space to rent for storage of the car and it's disassembled bits, as well as a location to paint it.
I use the car frequently, and at the outset wanted to just do a quick and easy respray over a 3 week period whilst my better half and our little one were away...... I ended up a fair bit more involved than that with the bodywork taking about 3 months with a whole bunch of life distractions getting in the way.
As we progressed with the fiberglass repairs, and the body prep the cars shape got better and better. Richard worked through some dodgy repairs on the bonnet (a hole which had been bogged up) which was the worst fitting panel.
https://www.dropbox.com/s/73ewuvexgr3f1 ... 2.jpg?dl=0
The high fill and blocking back process took a few iterations before I landed on the final shape with enough primer still on the car.
https://www.dropbox.com/s/xfmsjo92g1mcx ... 1.jpg?dl=0
https://www.dropbox.com/s/1ge2aqhyfk2p7 ... 6.jpg?dl=0
https://www.dropbox.com/s/2qimv1adm18l0 ... 8.jpg?dl=0
And last weekend I managed to finally get some paint onto the car.
https://www.dropbox.com/s/oriv36ysl032l ... 9.jpg?dl=0
https://www.dropbox.com/s/oriv36ysl032l ... 9.jpg?dl=0
https://www.dropbox.com/s/v32qcjisb7ef1 ... 7.jpg?dl=0
https://www.dropbox.com/s/v32qcjisb7ef1 ... 7.jpg?dl=0
https://www.dropbox.com/s/fmr3kka3d48kw ... 3.jpg?dl=0
Now to build that gearbox.....
I managed to limp the car back to the garage in 4th gear (was a short distance away).
It turned out of be a pretty terminal gearbox failure with the input shaft having lost all its teeth.
https://www.dropbox.com/s/8oxfc6unzmefl ... 3.jpg?dl=0
https://www.dropbox.com/s/f4lri16n98dow ... 7.jpg?dl=0
Like any good repair this is where my gearbox rebuild progressed to
https://www.dropbox.com/s/koak0swnx2pii ... 9.jpg?dl=0
https://www.dropbox.com/s/1q2be4e6wmxgz ... 0.jpg?dl=0
Nothing like a bit of scope creep! The thought process was while I've got the engine and gearbox out I should paint the engine bay..... and while I'm painting the engine bay I should paint the rest of the car.
I was lucky enough to have access to Richard Mann who helped with the fiberglass repairs. He also provided the space to rent for storage of the car and it's disassembled bits, as well as a location to paint it.
I use the car frequently, and at the outset wanted to just do a quick and easy respray over a 3 week period whilst my better half and our little one were away...... I ended up a fair bit more involved than that with the bodywork taking about 3 months with a whole bunch of life distractions getting in the way.
As we progressed with the fiberglass repairs, and the body prep the cars shape got better and better. Richard worked through some dodgy repairs on the bonnet (a hole which had been bogged up) which was the worst fitting panel.
https://www.dropbox.com/s/73ewuvexgr3f1 ... 2.jpg?dl=0
The high fill and blocking back process took a few iterations before I landed on the final shape with enough primer still on the car.
https://www.dropbox.com/s/xfmsjo92g1mcx ... 1.jpg?dl=0
https://www.dropbox.com/s/1ge2aqhyfk2p7 ... 6.jpg?dl=0
https://www.dropbox.com/s/2qimv1adm18l0 ... 8.jpg?dl=0
And last weekend I managed to finally get some paint onto the car.
https://www.dropbox.com/s/oriv36ysl032l ... 9.jpg?dl=0
https://www.dropbox.com/s/oriv36ysl032l ... 9.jpg?dl=0
https://www.dropbox.com/s/v32qcjisb7ef1 ... 7.jpg?dl=0
https://www.dropbox.com/s/v32qcjisb7ef1 ... 7.jpg?dl=0
https://www.dropbox.com/s/fmr3kka3d48kw ... 3.jpg?dl=0
Now to build that gearbox.....