Toying with idea of taller Metro 5th gear (to go with the already taller final drive)

[Christ]

Originally Posted by MadisonMPG

source:
Differentials (Open, LSD and so on)

I have a Lego Differential, but I can't find it I would demo it if I could.

Ok, yeah, you guys are right. I forgot that that spider gears divide the output speed between the two sides of the differential.

Hey, even I can be wrong once in awhile!

[Christ]

LOL DCB... I read that.

[MetroMPG]

Originally Posted by dcb

Probably completely impractical, but I do wonder if welding up custom axle halves (quarters?) and adapters and mounts so you can use a completely different gearbox

Ha. The thought crossed my mind, actually... would also have to come up with an adapter plate and potentially some adapter for the clutch/input shaft, no?

We'll see whether these two other machine shops have to say. My brother is dropping by one tomorrow for his own business, and is taking one of the 5th gear cogs with him (with permission to have the guy try cutting it).

I love the 1wd super overdrive idea!

[Christ]

You'd use the clutch and pressure plate/flywheel from the transmission, unless you could find a clutch disk for the transmission that would fit inside the pressure plate of the Geo's motor.

Without knowing the sizes, I couldn't be of any help. I'd have to look up the clutch diameter of the Suzi-clone and then cross reference it with others to find a close-but-not-quite-perfect-match.

Usually, if it's close, it works.

The best way to do it and see if it would work, though, is to put a used clutch disc from the new to you tranny into your pressure plate assembly and see if it will mostly mate up, or all the way mate up. The way we drive, a 75% match between the friction material and the pressure plate would be fine, I'd think.

1wd super OD -

Remove the longer axle, separate the axle shaft from the CV joints, put the outer joint back into the hub, bolt it in (so the hub doesn't come apart). Cut the stub off the inner CV joint, then weld some bar to it that you could bend around to a point where you could bolt it fast to the engine block.

That would allow the wheel to freewheel safely, while stopping one side of the transaxle's differential from spinning, thereby transferring all the torque to the one wheel... just don't put that wheel on a slippery surface...

Wouldn't be bad for a 1 hour experiment, though. (It only takes like 15 mins to remove a CV axle and 10 to disassemble it when you don't plan on rebuilding it.)

[ZeroFuel]

Hi D

We tried numerous sources in the states to have custom 5th gears built, but to no avail.

Any luck on your end?

[MetroMPG]

My brother took one of the 5th gear cogs to a couple of machinists. Neither have wire EDM. Both tried filing/cutting the steel.

One said, "no way - I'll go through too many cutting bits (?)" #2 said, "I'm potentially interested." I haven't had a chance to talk to #2 yet.

[Christ]

Originally Posted by MetroMPG

My brother took one of the 5th gear cogs to a couple of machinists. Neither have wire EDM. Both tried filing/cutting the steel.

One said, "no way - I'll go through too many cutting bits (?)" #2 said, "I'm potentially interested." I haven't had a chance to talk to #2 yet.

Cutting heads... they get dull, and you just replace them. He's concerned that he wouldn't be able to make money because of the cost of bits at his price versus what a fair price for the job would be, which is a valid concern, I suppose. One-off gear sets aren't easy to get made, unless they're prototypical for a mass runoff of them.

[MetroMPG]

Yep, cost of all the bits was the concern.

I talked to my brother today: mMachinist #2 is definitely interested and was going to investigate further by putting one of the 5th gear cogs on a lathe and removing its teeth. In other words: preparing the hub which would be inserted into one of the 2nd gear cogs.

If that operation went well enough (will know on Monday) and he still wants to go ahead, then I'll go visit him to talk over the rest of the details.

[ZeroFuel]

Good news D, we would need 1 set ASAP as our 1st unit is ready to be assembled. If you want me to be the guinea pig let me know. Thx

[Christ]

Sweet news! I wonder if I can get anyone to make me some custom transfer gears for Cara? I dunno if I'll need them, I'll have to see how the manual swap works out first.