When I made the water pump pulley tensioner bracket some time ago, I bolted it on top of the layshaft bracket and noticed that the vertical part of the layshaft bracket was not quite square to the block. When I had the pieces for the layshaft bracket laser cut I incorrectly specified 10mm holes in the CAD design when I needed 8mm holes. The holes ended actually up being roughly 10.6mm from the laser cutting, . I've never really been happy with this and it meant that the whole bracket could potentially be bolted up at be unacceptable angle to the layshaft.
The photo below is not the angle of the bracket when I first noticed the misalignment, but in the worst case scenario the bracket against the block could be rotated anti-clockwise (due to the larger holes) causing a significant gap at the top of the bracket between it and the layshaft assembly.
I cut the pieces of the layshaft bracket apart and to correct the hole sizes, drilled out the holes to 12mm, machined some pieces of tube (just over 12mm OD, 8mm ID) and press fitted them into the holes.
The layshaft was then inserted into the gearbox and ensuring that it was square to the engine (both vertically & horizontally), I tack welded the two bracket pieces together.
I then fully welded the bracket back together and added a pair of small triangular gussets.
With the water pump pulley tensioner bracket in place :
The photo below is not the angle of the bracket when I first noticed the misalignment, but in the worst case scenario the bracket against the block could be rotated anti-clockwise (due to the larger holes) causing a significant gap at the top of the bracket between it and the layshaft assembly.
I cut the pieces of the layshaft bracket apart and to correct the hole sizes, drilled out the holes to 12mm, machined some pieces of tube (just over 12mm OD, 8mm ID) and press fitted them into the holes.
The layshaft was then inserted into the gearbox and ensuring that it was square to the engine (both vertically & horizontally), I tack welded the two bracket pieces together.
I then fully welded the bracket back together and added a pair of small triangular gussets.
With the water pump pulley tensioner bracket in place :
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