My '72 1600 SSS

[broke]

Did some welding today. It's not good enough for Weld Porn or anything, but it's not bad enough for "Welding Fails" either.

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You can see the space I'm aiming to fit it into here. Hoses will be cramped, but I'll make it work somehow. Also if I ever do this again I'm going to use those weld on UN o-ring bosses, as it's damn hard to get the torch into the right spot when you have two male fittings side by side.

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Then welded this mounting strap on top. Still need to get an alloy fuel pump mount and weld it to this, then buy fuel pumps and start plumbing them in. Nabbed lots of R14 teflon hose before I left Hydraulink, so that should help keep costs down

[2 doors]

making progresss ,looks good

[85_Z31]

looks good nice work.

[broke]

Finished the surge tank, still waiting for my fuel pumps to arrive.

In the meantime I started ripping into this gearbox tonight - even with the factory repair manual I managed to lose 3 spring loaded ball bearings taking 6th gear off. Took a wee while to find them all too...

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Got this far. I need to invent or modify some special tools to go any further than this, might have a crack at that after work tomorrow.

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[torqued]

Lol, Is that still in your spare room?

[brocky41]

Lol - i dont have curtains like that in my shed.

I hope you covered the floor in plastic and cardboard before you started with that gearbox.

I like your surge tank and where its located - keep up the good work.

[broke]

Lol, Is that still in your spare room?

Not any more haha.

Followed the factory manual which says to use a puller and slide hammer to remove 6th gear. I tried for ages and couldn't get it to budge, even tried winding in the centre bolt of the balancer puller to the point where the threads in 6th gear hub started pulling out!

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Eventually I gave up and set it up like this on the bench - I think the "shock" force of the slide hammer is really necessary for pulling the gears and not having it solidly braced was absorbing that force.

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Many, many max effort slams later and it came off, so abruptly that I almost fell over backwards. Went scrabbling on the ground looking for springs and ball bearings again...

After that it wasn't too hard to get the centre casing off, then I ran out of time

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[broke]

This box was advertised as working but being hard to shift in the lower gears. I bought it thinking that was probably a good thing, as it's usually 4th that gives up and then everything explodes and it's useless Fortunately the gears look fine, there were an awful lot of metal fragments here though - the box has a big magnet sitting in the bottom of the casing as well as the one on the drain plug, neat touch I thought.

Upon closer inspection it looks to me that these shards are from 4th gear contacting the gear next to it and being eroded slowly, the synchro rings don't look too flash either. I'll know more once I disassemble the cluster, it looks salvageable to my untrained eye though.

[broke]

I think I found the issue.

That haggard looking metal collar thing is a bush for the shift fork where it slides on the shifter rod. The other damaged one was way worse - The teflon/bronze lining had completely disintegrated, the steel backing was all chewed up and the whole thing had dropped right out so the fork was flopping around like a cock in a sock.

That explains why I kept finding all those bits of plastic type fragments everywhere.

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It's a non standard sized 15x17 bush. Went to Saeco and got some 16x18 DU bushes hoping the extra interference on the OD would decrease the ID but it was still too sloppy. I'll ask about some proper sized ones tomorrow. Hopefully they can get something.

[2 doors]

good work, gearbox,s can be like voodoo black magic to work on.