5-speed lever fork repair kits now available!

[silverbullet]

OK I suppose it's strictly a mechanical thing but here's a bit of news:
I've been working on a DIY repair kit for 4-speed gear selector rod tips (the plastic bits that get worn and break off, leaving you with a sloppy gear lever even when everything else has been sorted) which I am currently durability testing on our syncro before going on sale.
I've applied the same principles to the 5-speed lever and have devised this:

which is infinitely preferable to this:

C/w comprehensive instructions, but fitting is well within anyone's abilities. All you need is patience, mole grips (or a small vice) and some epoxy glue.
The next piece of the puzzle will be remaking the guide blocks (shown here badly worn by a damaged lever fork):

This process will be made a lot easier with access to a factory production drawing and I hope to get the costs to a fraction of what I hear Heritage will be charging.

[scottbott]

Do not need them yet but would be interested in having some as spare parts

[silverbullet]

Now generally available (making more stock right now, should be ready to send out middle next week) for the bargain price of £22.50 + post and vat on top (sorry) = £28.80 to UK/Eurozone for either kit, syncro/4-speed or 5-speed.
I've already sent some to Australia and the US, so hurry before they're all gone

[DarkPoet]

Had this kit fitted yesterday & its made a massive difference to the gear change. Can actually get 1st now & the rest are much smoother.

Highly recommended

[silverbullet]

Thanks Dark Poet!

Some people have commented that silicone grease doesn't seem to be widely available in sensible quantities. A quick google for "silicone grease sachets" threw up just one £bay seller who bulk sells 7g sachets (not really enough for a gearshift) but does also sell 150g squeezy bottles. Enough for the entire gearchange, if you're lubing all the sliding bearings and the selector ball & socket I'd reckon.

RS also do a 100ml tube or 30g syringe but it's rather expensive at £6-odd.

[DarkPoet]

My tame mechanic isn't short of grease, if the state of my steering wheel is anything to go by.......

Seriously, he's a great bloke & commented on how easy it was to fit the kit. I was ready to throw hundreds at a new gearbox.......

[silverbullet]

Hot news: Kits now to be exclusively available in UK and Europe from Brickwerks.

Please give us a working week or so for stock to be transferred and listed.

Effective immediately. Don't go asking for any back-door sales 'cos there won't be any

Alloy guide blocks are still being investigated, getting nearer. Honest.

[silverbullet]

Fresh developments: I will now be offering a 5-speed gear lever repair service, with a quick turnaround for those panic breakages!

All levers will recieve the following:

Replacement plastic tips fitted
Straightening/re-setting
Reinforcement rod fitted (full length, internal, plug welded each end) to prevent future breakage and crack development.
Re-welding of broken levers will also be done, once I have a jig made up.

Simply send your lever without the ball & mounting plate, spring, collar or knob, nicely scraped and washed (parrafin is ok) with your details attached.

All-in price of £55 inc. post and vat.

Please note: This service will not include replacement of any missing plungers, springs, bellows or buffer caps. Only suitable for 14mm levers.

[silverbullet]

The long-awaited alloy lever guide wedges are about to start coming on-stream. We had a bit of a problem with tooling and the factory drawing - it didn't show everything! After more investigation and tool investment, they are now looking good.
I have run a few prototypes off and they will get tested straight away, but I don't anticipate any problems at all.
Will post up pics and prices asap.

[silverbullet]

Nearly there...

[silverbullet]

At last! First finished one off tools so here we go! Pics in a bit as the camera's at home but I'm just about done today

[silverbullet]

Here you go, you lucky people! This is the very first one finished, looking a bit sharp. They will all get a light dressing to round the corners off.





Only one small deviation from the originals: I have elected not to machine on the two small bevels on the top. They don't do anything other than simply saving VW the cost of material on the casting and you don't want to pay for me to machine it off!

I'll be asking Brickwerks if they want to stock them before posting any price up

[Aidan]

[Oldjets]

Machine shop porn - I like it!

Saving up for a set right now.

Oldjets

[Oldiebut goodie]

They don't look like machine shop hands.(wearing a ring also!) What barrier cream do you use?