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benozoval56
Samba Member
Joined: April 13, 2022
Posts: 25
Location: Seacombe Gardens
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 Posted: Tue Jul 12, 2022 4:12 am Post subject: Re: Building a strong gearbox with 95% OEM parts |
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| Clatter wrote: |
| benozoval56 wrote: |
| Clatter wrote: |
This is a great thread.
Next is for the details of doing all this,
And it'll get long and off-track for sure! 
Like,
What drill bits are hard enough to drill holes in the hubs?
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what size holes am I drilling here please? |
| ngobet wrote: |
Drill 3mm holes in the hub. . |
Just have to read the thead..  |
have read too many times and still missed it  |
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ALB
Samba Member
Joined: August 05, 2008
Posts: 3474
Location: beautiful suburban Wet Coast of Canada
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| Posted: Tue Jul 12, 2022 6:40 am Post subject: Re: Building a strong gearbox with 95% OEM parts |
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| benozoval56 wrote: |
| Clatter wrote: |
| benozoval56 wrote: |
| Clatter wrote: |
This is a great thread.
Next is for the details of doing all this,
And it'll get long and off-track for sure!
Like,
What drill bits are hard enough to drill holes in the hubs?
|
what size holes am I drilling here please? |
| ngobet wrote: |
Drill 3mm holes in the hub. . |
Just have to read the thead.. |
have read too many times and still missed it |
Carbide bits will drill holes in hardened trans parts. Be aware that they aren't cheap, and are somewhat fragile.
A lot of trans parts are surface hardened to a depth of .030"- .040". The gears are softer, inside, but if you're drilling all the way through be careful when hitting the hardened material on the other side. When you break through the surface, if you're too aggressive you'll break the bit. Up here carbide bits are expensive. I've broken 2 1/8" ($20 each) and 1 1/4" bit (over $50- guess how loud I yelled when I broke that 1!). The shift forks weren't especially hard, but thought I'd post that pic to show what's possible...
_________________
On a lifelong mission to prove (much to my wife's dismay) that Immaturity is Forever!! |
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nsracing
Samba Member
Joined: November 16, 2003
Posts: 9183
Location: Northern Virginia
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| Posted: Fri Jul 15, 2022 3:27 am Post subject: Re: Building a strong gearbox with 95% OEM parts |
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YOu people certainly have too much time on your hands.
I once saw a flywheel w/ several dozens drill holes in it. Maybe improve the performance of pistons by drilling right thru the top of it? |
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benozoval56
Samba Member
Joined: April 13, 2022
Posts: 25
Location: Seacombe Gardens
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| Posted: Sat Jul 30, 2022 7:58 pm Post subject: Re: Building a strong gearbox with 95% OEM parts |
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| ngobet wrote: |
Let's move to end play....
The dark circlip is the 002 version, thinner than the 091. On this picture, you can see that the hub was machined to position it correctly.
The next picture is after removing the circlip, when the hub is push against the front 091 circlip (top). When machining the hub, measure the difference of thickness of the circlip (usually 002 is 1.49mm, 091 is 2.47mm). 4th gear will have around 0.25mm play and 3rd 0.50mm play (see...). You will then machine around 0.80mm off the hub (MEASURE YOURSELF ON YOUR PARTS) to split the endplay between the 2 gears, and both gears will end with 0.37mm.
Now all your idler gears are well oiled and have sufficient endplay.
Don't do the handpacking of the needle bearing as suggested by Berg. It brings too much heat in the gear. Look for the early caged needle bearing, there is more room for oil. |
my 3rd/4th gear slider has a groove on the "teeth" and I cannot remember which way it came off the shaft. Is there a diagram that shows which way this should be installed please? |
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nsracing
Samba Member
Joined: November 16, 2003
Posts: 9183
Location: Northern Virginia
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| Posted: Sat Jul 30, 2022 9:02 pm Post subject: Re: Building a strong gearbox with 95% OEM parts |
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Looks like you are going far from the reservation. Maybe you are one of those who just wakes up one day and be good at transmissions. YOu may want to slowdown cutting stuff. Bernie Bergman did many things to the VW engines. -just saying.
I started out sticking exactly to the Bentley manual when I built my first trans and used that for years -put me thru school. Then somewhere along there, I built many more for others. Since I have had my machines I did more mods required in drags and learned a bit more on what not to do on the parts.
If this is gonna be your trans, so be it - modify as much as you want. But I sure hope you will not do these to customers' trans if you ever decide to do them for money.
But I am truly enjoying myself watching this thread. |
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benozoval56
Samba Member
Joined: April 13, 2022
Posts: 25
Location: Seacombe Gardens
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| Posted: Sun Apr 02, 2023 1:20 am Post subject: Re: Building a strong gearbox with 95% OEM parts |
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Quick question on the Super Diff.
Can 10T spiders and 15T side gears be used without ant further modifications required? |
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[email protected]
Samba Member
Joined: May 17, 2003
Posts: 4853
Location: Harmony, PA
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| Posted: Sun Apr 02, 2023 8:26 pm Post subject: Re: Building a strong gearbox with 95% OEM parts |
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| Most that use the 15/10 tooth combo gears in a swing axle diff are using two spider gears in an oem housing. If you want a super diff, you’re going to have to find a NLA used/nos one specifically made for the 15/10 tooth gears. All of the modern new commonly available super diffs are made for the more common 17/11 combos, and the 15/10 gears will not mesh properly with 4 spider gears. |
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