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Sleeving 4th idler gear
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scotty timmerman
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Joined: January 10, 2010
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Location: gigharbor W.A
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PostPosted: Tue May 13, 2025 6:09 pm    Post subject: Sleeving 4th idler gear Reply with quote
I just received a .77 4th gear set and have found that the inner bore of the idler gear was poorly machined. The surface is rough and there is a corkscrew pattern that feels like it’s high. The bore is .005” larger compared to other gear sets I have measured with calipers. I think if it was honed out it would then be to large. Does anyone know the tolerance for this bore? I’m thinking it needs to be bored out and have a sleeve installed To be usable. Sleeve would be a type of bronze and be press fit. This gear will be used as a 5th on a berg 5 speed. What do others think?


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modok
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Joined: October 30, 2009
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PostPosted: Tue May 13, 2025 7:31 pm    Post subject: Re: Sleeving 4th idler gear Reply with quote
Perhaps.... oversize roller bearings?
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Bruce
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Joined: May 16, 2003
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Location: Left coast, Canada
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PostPosted: Wed May 14, 2025 1:41 am    Post subject: Re: Sleeving 4th idler gear Reply with quote
scotty timmerman wrote:
Sleeve would be a type of bronze and be press fit.

I wouldn't use bronze. It needs to be hardened to withstand the contact pressure of the narrow edge of the rollers.
If you want to make a sleeve, make it from an old damaged VW gear. That way it's the right steel and the right hardness. Then make it a press fit. Use the freezer for the sleeve and heat the gear before pressing together. Then you can tack it with the TIG in a couple of spots.
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