Cut/weld gearbox cluster access in chassis leg

[Iain]

Anyone done this on a Nova? Any chance of some measurements or pics how much needs trimming away and welding back up?

Looking to be able to remove an F20 end plate/cluster without having to drop the engine to one side.

[Johnny A]

I have, but not to allow the end plate to be removed - I did it for clearance. Pics in my projects thread.

[Iain]

Thanks looks like you've removed a fair amount, I'll have to measure up and see how little I can get away with removing as was hoping to just take the lip off and stitch it up...

[Andy]

Are you wanting to do this for swapping them over quickly?
I never found it particularly difficult to drop the mount on mine tbh,didn't take much.

[Novasport]

Removed the cluster on mine, never again. Took ages to get the casing to stop leaking gearbox oil. It is better but still leaks :(

[craig green]

Although I havent done it, I have thought about how I would want it done. I would cut a neat arc right into both skins of the chassis leg as generous as necessary space/clearance wise, then instead of trying to make the chassis leg form a seam again, use a 2" strip of steel formed to follow the arc in the leg & weld that in around the arc.

[Iain]

Yep what I expected would be the approach Craig, just box it out again

Looking at fitting another F20 to trial it out, if I like it I may want to tweak the 5th gear ratio on it so figured it may be a good time to hack it out a bit

The more I think about how often and useful it'll be the less I can be arsed to do it TBH lol

[burgo]

You'll only need to undo the 3 gearbox mount bolts for it to drop enough surely?

[mowgli]

seriously, just how often are you planning to change clusters?
the only way do successfully sort out the sealing of the gasket is to completely drain the box of oil & run a cloth round inside to get all traces of oil out before reassembling it..

[RallyMarshal]

Did my Astra Mk2 recently Iain..

http://www.teamrallymarshal.co.uk/gallery/TarmacAstraGTE/TarmacAstraGTE_Shell104.jpg

Basically marked then cut it from the pointy down bit up to the bottom lip of the chassis leg and then used a decent size knocking stick to level them out. Ste then fully welded it together (after this pic...)

Paul...

[Stuart]

Or use good silicone....

[mowgli]

the problem is keeping all traces of the oil away from the mating surfaces, not the sealant

[Andy]

Or use good silicone....
wurth rtv
Put hundreds of clusters back in/diff pans back on,never had one leak yet.

[Iain]

seriously, just how often are you planning to change clusters?
the only way do successfully sort out the sealing of the gasket is to completely drain the box of oil & run a cloth round inside to get all traces of oil out before reassembling it..

Planning to put a new box in, then potentially change 5th gear a few times. May also be nice to be able to pick a 5th gear depending on a trackday/show season for example. Figured if I need the end plate off more than twice then it'd be time well spent as I hate dropping it off it's solid mounts and twisting it in the bay as the bottom pulley is already close to the chassis leg.


Paul that looks good, I might see if I can do similar on the Nova and see how much clearance I'd gain. If enough to do the 5th gear swap then happy days.

[Stuart]

the end plate for 5th will come off without needing to cut much imho. and its a piece of wee to keep that one clean :)

[L14MNP]

VOSA would have something to say about it (and your other monocoque mods), mind!
Be careful.

[letvalva]

When I was running f20 on my gsi with a let in I changed clusters and I just took the three bolts off on front mount of the box. Was a piece of piss to do. About an hour later I was out spinning wheel like I a nob again

[Iain]

OK looking at it you can't 'open out' the chassis leg to allow you to remove the whole cluster, you'd end up hacking out most of the chassis leg.

Updated WIP to come soon but I've basically taken back the lip at the bottom, most of it not beyond the spot welds I bet, shaped it up and ran a weld along the bottom edge to stop the seam from separating. This should allow me to squeeze off the end cover plate to tickle 5th.

http://iainel.co.uk/images/forums/Misc/rps20140910_154601_771.jpg

[8valve-craig]

I think its a great idea. The Rookie Rods all do it for the same reason.

I did something similar on the other side of the car to make clearence for the oil pump.

http://i995.photobucket.com/albums/af79/smith9051/Nova%20on%20bike%20carbs/IMG_4404_zps0b4ba70e.jpg

[Iain]

Remember that from your wip Craig. I'd be more tempted to do something like that during the initial build for now its just a nice to have while I'm doing the box so I'll settle for an end cover trimming. Means I can pull the input shaft for clutch changes easily also.