Today's task was to design a custom bracket to hold the layshaft in place. I firstly removed the inner CV cup and shaft from the gearbox. You can buy a tool to do this but it's easy to make one yourself. Last weekend I went to our local tip which recycle and re-sell furniture, toys, general household items, wood, tiles, paving, steel etc etc I got heaps of steel for a bargain price of $5. I got most of it to make a rotisserie for the shell (which is partailly finished already and will post pics later when it's finished) but used a bit of the scrap steel and cut a 50mm wide opening in it to go around the CV cup base. A hammer is then used to hit the end of the steel plate which compresses the circlip on the spline and levers the shaft out of the gearbox.
It's time to design the bracket with the layshaft now inserted in the gearbox (the Corolla shaft has the same number of teeth on the spline as the Starlet and slips straight in). The 4AGE layshaft doesn't a have a cirlclip to hold the shaft in the gearbox but the bracket will hold the whole thing in place.
I mocked up a design using 9mm MDF (the final design will probably be ~9mm steel), firstly cutting a 76mm hole with a jigsaw and driling some bolt holes for the main part of the bracket and then some trial and error to get some bracket shapes.
The final design below will have a couple of gussets added to brace between the two main steel plates and the top section of the vertical plate will be bent to the left (you can see the lines I've marked on the wood for the angle) to allow third bolt hole to be used. The plates could be cut using a Oxy torch (messy) or plasma cutter (not so messy) but I plan to knock up a design in CAD so I can get the pieces laser cut - nice and accurate especially for the circular sections around the bearing casing.
It's time to design the bracket with the layshaft now inserted in the gearbox (the Corolla shaft has the same number of teeth on the spline as the Starlet and slips straight in). The 4AGE layshaft doesn't a have a cirlclip to hold the shaft in the gearbox but the bracket will hold the whole thing in place.
I mocked up a design using 9mm MDF (the final design will probably be ~9mm steel), firstly cutting a 76mm hole with a jigsaw and driling some bolt holes for the main part of the bracket and then some trial and error to get some bracket shapes.
The final design below will have a couple of gussets added to brace between the two main steel plates and the top section of the vertical plate will be bent to the left (you can see the lines I've marked on the wood for the angle) to allow third bolt hole to be used. The plates could be cut using a Oxy torch (messy) or plasma cutter (not so messy) but I plan to knock up a design in CAD so I can get the pieces laser cut - nice and accurate especially for the circular sections around the bearing casing.
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