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yggdrasil Samba Member
Joined: March 07, 2010 Posts: 240 Location: New Mexico
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Posted: Mon Jan 30, 2023 7:38 pm Post subject: Gas to Diesel clutch lever fabrication. |
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cant find the diesel clutch lever, wondering if anyone has had any luck cutting rotating and welding one...
I think i can cut slice it rotate and stick it back to gether.
Any comments? |
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outcaststudios Samba Member
Joined: February 09, 2015 Posts: 1732 Location: Maine
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Posted: Mon Jan 30, 2023 7:44 pm Post subject: Re: Gas to Diesel clutch lever fabrication. |
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i dont see why you cant use a tig welder to join it. i would use silicon bronze filler rod but stainless would work too. the bronze stretches more instead of snapping. obviously be sure to clean both surfaces and use 100% argon if you can for heat. _________________ '88Doka JX td
'69 westy
(rip)couple bugs
(rip)three type III"s
(rip) '81 vanagon
a bunch of french stuff,and 9 motorcycles.
https://www.thesamba.com/vw/classifieds/detail.php?id=2573791 |
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yggdrasil Samba Member
Joined: March 07, 2010 Posts: 240 Location: New Mexico
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Posted: Mon Jan 30, 2023 8:02 pm Post subject: Re: Gas to Diesel clutch lever fabrication. |
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It's cast steel right? |
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outcaststudios Samba Member
Joined: February 09, 2015 Posts: 1732 Location: Maine
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Posted: Mon Jan 30, 2023 8:04 pm Post subject: Re: Gas to Diesel clutch lever fabrication. |
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its an alloy of steel thats cast,yes, i havent ever done this to this exact part but i have to other parts. did you test with a magnet? i doubt its aluminum. _________________ '88Doka JX td
'69 westy
(rip)couple bugs
(rip)three type III"s
(rip) '81 vanagon
a bunch of french stuff,and 9 motorcycles.
https://www.thesamba.com/vw/classifieds/detail.php?id=2573791 |
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syncrodoka Samba Member
Joined: December 27, 2005 Posts: 12005 Location: Santa Cruz, CA
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crazyvwvanman Samba Member
Joined: January 28, 2008 Posts: 9923 Location: Orbiting San Diego
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Posted: Mon Jan 30, 2023 8:42 pm Post subject: Re: Gas to Diesel clutch lever fabrication. |
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I wonder if you could just take a gas one and file one of the 4 splines off so it can rotate on the shaft by that amount?
Also Weddle was selling cross shafts for a while that had extra grooves to allow the lever to be mounted at different rotational positions.
Don't know if either approach would do the job but I'd look at them.
Mark
yggdrasil wrote: |
cant find the diesel clutch lever, wondering if anyone has had any luck cutting rotating and welding one...
I think i can cut slice it rotate and stick it back to gether.
Any comments? |
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Sodo Samba Member
Joined: July 06, 2007 Posts: 9603 Location: Western WA
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Posted: Mon Jan 30, 2023 8:52 pm Post subject: Re: Gas to Diesel clutch lever fabrication. |
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Is it feasible to cut the cross-shaft, rotate the splined end then weld it?
Then it's only "steel".
Could be mild steel.
Try filing it. _________________
'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb |
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syncroserge Samba Member
Joined: November 26, 2005 Posts: 553 Location: Okotos, Alberta, Canada
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Posted: Mon Jan 30, 2023 9:05 pm Post subject: Re: Gas to Diesel clutch lever fabrication. |
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Even simpler to modify the clutch slave bracket. I'll look tomorrow for the one I modified.
It worked fine for years until I found a complete diesel bellhousing. |
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ALIKA T3 Samba Member
Joined: July 30, 2009 Posts: 6349 Location: Honolulu,Hawaii and France
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Posted: Mon Jan 30, 2023 11:27 pm Post subject: Re: Gas to Diesel clutch lever fabrication. |
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Sodo wrote: |
Is it feasible to cut the cross-shaft, rotate the splined end then weld it?
Then it's only "steel".
Could be mild steel.
Try filing it. |
Or just reweld the forks for the throw out bearing, that'd be the easiest of all _________________ Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget |
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?Waldo? Samba Member
Joined: February 22, 2006 Posts: 9752 Location: Where?
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Posted: Tue Jan 31, 2023 8:50 am Post subject: Re: Gas to Diesel clutch lever fabrication. |
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yggdrasil wrote: |
cant find the diesel clutch lever, wondering if anyone has had any luck cutting rotating and welding one... |
Let me guess, your next thread is going to be about how you want to cut and weld the gasser slave bracket to turn it into the diesel version. Do you have way more time than money? Is your time worth so little? What about when you're out on a trip and your welded clutch lever breaks or cobbled slave bracket breaks? This is why I suggested in your other thread to get a used diesel bell housing complete with clutch release lever AND slave bracket!
?Waldo? wrote: |
I agree with Mark. Get it all as a complete unit with clutch lever and slave bracket.
No affiliation: https://www.ebay.com/itm/185224838699
Quality Geman in Montclair also probably has one available. |
yggdrasil wrote: |
oh well too late. My tranny guy says we should be pretty ok to go. Just a little bit of extra work. |
Sell the incomplete bell housing you already got to someone else who is replacing their messed up diesel bell and already have the other parts. |
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vanis13 Samba Member
Joined: August 15, 2010 Posts: 3092 Location: ABQ NM USA.... Except when not
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Posted: Tue Jan 31, 2023 8:54 am Post subject: Re: Gas to Diesel clutch lever fabrication. |
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wonder if the slave pushrod length could me modified to work. _________________ 83.5 Westy with Subaru 2.5, 4 spd manual, center seat, COLD A/C on 134a!, Winter camp heated with an Espar B4 gasoline furnace
www.SuperVanagon.com - some stuff I make |
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?Waldo? Samba Member
Joined: February 22, 2006 Posts: 9752 Location: Where?
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Posted: Tue Jan 31, 2023 8:59 am Post subject: Re: Gas to Diesel clutch lever fabrication. |
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All of the suggestions to modify OTHER parts in order to compensate for the desire to avoid purchasing the stock readily available parts seem crazy to me. I already posted a link to a complete diesel bell housing that includes both clutch lever and slave bracket and it took all of 10 minutes of searching to find it. $170 is a CHEAP way to avoid an ongoing current and future nightmare!
Imagine being the next owner of the van when one of the parts breaks on a trip and you have no awareness of the customization! |
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syncroserge Samba Member
Joined: November 26, 2005 Posts: 553 Location: Okotos, Alberta, Canada
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Posted: Tue Jan 31, 2023 9:07 am Post subject: Re: Gas to Diesel clutch lever fabrication. |
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I modified the slave bracket way back in the '90s when finding these parts was way harder than it is today.
The minute I got my hands on the real VW parts I slapped them on. I am with Waldo on this.
This stuff is not that hard to find.
On the other hand a slave bracket I modified for a friend is still going strong 20+ years later... |
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yggdrasil Samba Member
Joined: March 07, 2010 Posts: 240 Location: New Mexico
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Posted: Tue Jan 31, 2023 9:21 am Post subject: Re: Gas to Diesel clutch lever fabrication. |
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Wow! Great responses, this was putting me into serious depression and now i feel like there are some options.
I like the idea of just adding some splines to the shaft.
I also think idea of grinding down one of the splines on the inside of the lever to rotate it might work.
I did look at the throw-out bearing arms and that would also work but might be a little more work.
I'll let you know.
Syncroserge, let me see photos of what you have done to the slave bracket...
Thank you! |
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dobryan Samba Member
Joined: March 24, 2006 Posts: 16502 Location: Brookeville, MD
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crazyvwvanman Samba Member
Joined: January 28, 2008 Posts: 9923 Location: Orbiting San Diego
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Posted: Tue Jan 31, 2023 10:12 am Post subject: Re: Gas to Diesel clutch lever fabrication. |
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If it makes the angle right then this sounds like the way to go.
A little careful work with a file to remove a single spine inside the gas lever.
The risk is low as gas levers are not hard to find.
Plus it still works if you need to replace the cross shaft down the road.
Did you already locate a diesel clutch slave bracket?
I've been meaning to look though my tranny parts piles.
I used to do a lot of work with diesel vans.
Mark
yggdrasil wrote: |
.....
I also think idea of grinding down one of the splines on the inside of the lever to rotate it might work..... |
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yggdrasil Samba Member
Joined: March 07, 2010 Posts: 240 Location: New Mexico
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Posted: Tue Jan 31, 2023 10:25 am Post subject: Re: Gas to Diesel clutch lever fabrication. |
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crazyvwvanman wrote: |
If it makes the angle right then this sounds like the way to go.
A little careful work with a file to remove a single spine inside the gas lever.
The risk is low as gas levers are not hard to find.
Plus it still works if you need to replace the cross shaft down the road.
Did you already locate a diesel clutch slave bracket?
I've been meaning to look though my tranny parts piles.
I used to do a lot of work with diesel vans.
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Agreed, I did some quick measurements and I think one spline would move it to mostly the same angle.
Contrary to what everyone thinks, these parts are hard to find, The ebay posting listed is russian and does not ship to u.s.. I have scoured for 251141713C . with no luck.
Let me know if you have a bracket (or even the lever!), I was planning on fabbing it up.. somehow. Saving that time would be awesome.
Thanks. |
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syncroserge Samba Member
Joined: November 26, 2005 Posts: 553 Location: Okotos, Alberta, Canada
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Posted: Tue Jan 31, 2023 10:49 am Post subject: Re: Gas to Diesel clutch lever fabrication. |
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It is 0 F here so know that I only braved the cold to dig those parts out of oblivion because
you are from New Mexico and my wife and I are in love with New Mexico
If you put the wbx bracket on the diesel bellhousing it is obvious the difference is small.
Cut the mounting tab at the upper left of the bracket, grind to size, bolt it to the diesel starter
on the diesel bellhousing.
The diesel bellhousing is thicker than the wbx, plus the thickness of the starter so you need to keep
the angle of the bracket correct, tack in place then remove and weld properly.
I don't know why VW made the diesel parts quite different from the gas ones.
But as long as you get the geometry right all the above suggestions will work. |
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yggdrasil Samba Member
Joined: March 07, 2010 Posts: 240 Location: New Mexico
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Posted: Tue Jan 31, 2023 11:09 am Post subject: Re: Gas to Diesel clutch lever fabrication. |
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syncroserge wrote: |
It is 0 F here so know that I only braved the cold to dig those parts out of oblivion because
you are from New Mexico and my wife and I are in love with New Mexico |
Man! Thank you so much! That is exactly what I needed!
I have a chunk of land north of Santa Fe. I have a small camper set up as an air bnb. If you ever want to spend some time send me a message and I'll make sure you are taken care of. I could even wrangle up some lift tickets if that's your thing.
Thank you Syncoserge. |
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valvecovergasket Samba Member
Joined: October 10, 2018 Posts: 1491 Location: pnw
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Posted: Tue Jan 31, 2023 11:34 am Post subject: Re: Gas to Diesel clutch lever fabrication. |
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yggdrasil wrote: |
I think i can cut slice it rotate and stick it back to gether.
Any comments? |
even assuming your time and effort are completely free - if its off a handful of degrees and you have to mess with throw/lack of throw issues, that seems like an annoyance thats well worth the 23EU to skip
thats not to mention the bracket, etc
but, you do you! post the results _________________ MegaSquirt resource - SpitfireEFI.com
gone, but not forgotten: '83 tdi westy - swap thread |
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