Z320 Posted August 19, 2020 Author Report Share Posted August 19, 2020 Thank you Roger, also a good idea! BEST idea is always to ask soneone before you do something if you feel not safe. Quote Link to post Share on other sites
Kamphausen Posted August 21, 2020 Report Share Posted August 21, 2020 (edited) Looking at http://mazdaepc.com/parts/MX-5/AENA01/C1/1720/ it may be a good idea to unmount the shift fork to be able to unmount the whole gear lever case? Peter Edited August 21, 2020 by Kamphausen Quote Link to post Share on other sites
Z320 Posted August 21, 2020 Author Report Share Posted August 21, 2020 Hi Peter, I want to avoid doing this and do not expect any benefit doing this. But thank you very much for the link. Marco, waiting for a tool Quote Link to post Share on other sites
Z320 Posted August 24, 2020 Author Report Share Posted August 24, 2020 (edited) I don't want to tell you stories about what doesn't work, just take sharp drills up from 4 mm in steps of 0.5 mm, a lot of oil and drill it out. Take care not to slide through and not damage the aluminum housing this way. Edited August 24, 2020 by Z320 Quote Link to post Share on other sites
Motorsport Mickey Posted August 24, 2020 Report Share Posted August 24, 2020 That looks a good result. Mick Richards Quote Link to post Share on other sites
Z320 Posted August 25, 2020 Author Report Share Posted August 25, 2020 (edited) Yeah, to lift off the shifter housing should be an easy job now? Before I placed two punches with the distance between them (165 mm) to make all parts the same distance shorter. # Now just remove the 4 bolts, slip the housing backwards and the same time the "shifter block" off from the shaft? That's great, fast and easy! But when I removed the 4 bolts I realized - and wondered about - how generous wide the 4 holes are drilled, about 9.5 mm for M8! How do they adjust and bolt the housing in the factory in the correct position this way? ? ? §$)!&%!@@!! - with 2 dowels! They unable me to slide back the housing. And the little play in guides in the gearbox and in the housing unable me to lift the housing over the dowels. Well, time for a short brake and think about: to open the gearbox or looking for another way..... On the front bolts two short cuts left and right of the tube? Edited August 25, 2020 by Z320 Quote Link to post Share on other sites
Waldi Posted August 26, 2020 Report Share Posted August 26, 2020 Hi Marco, can you shorten the casting (and the shaft) once it is removed by 165 mm with machining Once you have removed it? If that is already the plan or not a good idea sorry, I do not follow your project in detail. Cheers, Waldi Quote Link to post Share on other sites
Z320 Posted August 26, 2020 Author Report Share Posted August 26, 2020 Hi Waldi, 165 mm is more than I can make it shorter, I could also punch 180 mm. With the housing removed my idea is to drill it from behind for the shaft going through (later I will plug it). So I will slide the housing forward and make it shorter step by step, always shure the shaft slides easy / the housing is axial correct. Finally I measure perhaps 17 mm (or what ever) between the 2 punches, so I have to drill the shaft 165 - 17 = 148 mm in distance from the factory drill, make the shaft 148 mm and the tube 148 mm shorter and can calculate how long the offset for the gearshift leaver must be. Any other ideas are welcome. Ciao, Marco Quote Link to post Share on other sites
Z320 Posted August 26, 2020 Author Report Share Posted August 26, 2020 I hope this post is not too much detailed... Quote Link to post Share on other sites
Waldi Posted August 26, 2020 Report Share Posted August 26, 2020 Sounds like a good plan Marco. You could Consider to tilt the lever a bit back or forwards (Probably forwards if you would re-locate a bit less than desired) in the final position to allow easier gear selection once the box is installed. Waldi Quote Link to post Share on other sites
YOW500 Posted August 26, 2020 Report Share Posted August 26, 2020 Hi All. Referring to my previous picture of the gear lever set up. Vitesse have done the same as Marco is proposing. Vitesse moved the gear lever forward by about 45mm with a small extension plate welded to the original Mazda gear lever base. As you can see by the picture the gear lever itself still does not come to the original location, more or less in the centre of the tunnel opening. I further modified my Vitesse gear lever by making the extension plate even longer. About 75mm brings the gear lever into about the correct position. For the side screen cars with their upright gear lever this is a real improvement over the standard Vitesse set up. From inside the car it is hardly noticeable. With the TR6 car, the Vitesse set up is much more acceptable. Well done Marco, all really interesting. Russell Quote Link to post Share on other sites
Z320 Posted August 26, 2020 Author Report Share Posted August 26, 2020 (edited) challenge solved Edited August 28, 2020 by Z320 Quote Link to post Share on other sites
AndyR100 Posted August 26, 2020 Report Share Posted August 26, 2020 Great progress Marco! Well done ...... Andy Quote Link to post Share on other sites
Motorsport Mickey Posted August 26, 2020 Report Share Posted August 26, 2020 (edited) Marco you are very patient and a deep thinker...excellent, great job ! Mick Richards Edited August 26, 2020 by Motorsport Mickey Quote Link to post Share on other sites
stillp Posted August 26, 2020 Report Share Posted August 26, 2020 12 hours ago, Z320 said: I hope this post is not too much detailed... No, not detailed enough! An interesting project, not many would be skilled enough or brave enough to take it on. Pete Quote Link to post Share on other sites
Z320 Posted August 28, 2020 Author Report Share Posted August 28, 2020 (edited) tool making for the lathe the next photos should be self explaining first fit here the housing touches the gearbox 140 mm, but 10 mm more I want to go forward Edited August 29, 2020 by Z320 Quote Link to post Share on other sites
Hamish Posted August 29, 2020 Report Share Posted August 29, 2020 Wow there is certainly Problem solving matched to engineering skill here. Quote Link to post Share on other sites
boxofbits Posted August 29, 2020 Report Share Posted August 29, 2020 Hi Marco Is it possible to reverse what's left of the housing onto the shaft, and would this bring the gear lever opening nearer. Does it matter if it is back to front. Or plane some material from the top of the tailshaft housing? Or are these suggestions foolish? Kevin Quote Link to post Share on other sites
Z320 Posted August 29, 2020 Author Report Share Posted August 29, 2020 (edited) Your last suggestion is what I already do. Works fine, currently the distance is 9 mm, 7 should be possible Edited August 29, 2020 by Z320 Quote Link to post Share on other sites
boxofbits Posted August 29, 2020 Report Share Posted August 29, 2020 2 minutes ago, Z320 said: Your last suggestion is what I already do. Works fine, currently the distance is 9 mm, 7 should be possible Okay good luck Quote Link to post Share on other sites
Z320 Posted August 29, 2020 Author Report Share Posted August 29, 2020 (edited) This it looks like after remove some material off All you need are some files, patience and patience as I suggested the shaft still in its position and going through the housing was very usefull distance is now reduced to 6.5 mm another 3 mm would be possible and still have the two holes to fix the housing, up to maximal 14 mm, but only with cutting the holes half away, so I did not next issue was what I expected on the right side: parts of the housing (not the housing itself!) touch the gearbox first preparing the cover with a file next the gearbox itself fits now next the right side (another day) Ciao, Marco Edited August 30, 2020 by Z320 Quote Link to post Share on other sites
Drewmotty Posted August 30, 2020 Report Share Posted August 30, 2020 Great stuff Marco. Quote Link to post Share on other sites
RogerH Posted August 30, 2020 Report Share Posted August 30, 2020 Hurry up - the suspense is killing me Roger Quote Link to post Share on other sites
Z320 Posted August 30, 2020 Author Report Share Posted August 30, 2020 (edited) The suspense about the end of chapter 2 or of the hole story? Edited August 30, 2020 by Z320 Quote Link to post Share on other sites
boxofbits Posted August 30, 2020 Report Share Posted August 30, 2020 (edited) Hi Marco Out of interest could you slide the housing on backwards and send a photo. I wanted to see how far it would go if pushed on back end first? I realise this might not be possible if some of the rear of the housing hits the tailshaft housing.....and whether the bolt holes in the housing would be anywhere near the threads in the tailshaft? Kevin Edited August 30, 2020 by boxofbits Quote Link to post Share on other sites
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