Still not quite finished with the rear axle
I've fitted longer studs and I'm making the spacers for it once that's done I can fit the wheels and set up the panard rod
So moving on from that I still had the speedo trigger to sort out so after some head scratching and a day on the mill/lathe this is what I came up with
I made the wheel from aluminium and the teeth are made from a stainless steel (it's not a good quality stainless because its magnetic?)
And I screwed them on so I can remove or add depending on how accurate the speedo is
I worked out from the old wheel and its new position (propshaft) that it should have 14 teeth
So il come back to that soon
So next on to the gearbox and clutch
The old 5 speed out and next to the new 6 speed
Aprox 100mm longer than the old box
As I mentioned at the start of part 2 the clutch was only just holding the torque
And as I had to replace the clutch due to the new box having a different input shaft it made sense to replace it with something better
On closer inspection you can see the old clutch hadn't bedded in fully yet so with a few more miles it would of probably been ok
With the clutch centre plate and 6 speed box a direct replacement it was over to the gear selector
I wanted to improve the feel and make it more shall we say "clunk clunk" like a race car
So I started off with the way the selector fits to the car
it normally fits via a rod and rubber bushes each end
This is what I came up with its a cheap eBay quick shifter in a home made housing and it bolts in to the transmission tunnel
Getting the selector rod right was a nightmare the tunnel in the Volvo is offset and with the new box being longer the angle the selector needs to work at means it has to be spot on
It took two days of grovelling under the car cutting welding modifying cursing and head scratching
But finally made the rod and got it working perfectly "like a Race car"
Next the gearbox mount
I over complicate things sometimes but this was a pretty straight forward problem to sort
A simple bracket a jag engine mount (compact and strong)
The original Volvo gearbox cradle can go on either way round so what I've done is
Keep one side for the 5 speed gearbox mounts and modified the other side to take the 6 speed gearbox mounts
So this way I can swop the 5 speed back if needed I have a 5 speed mount/selector/propshaft etc and the same for the 6 speed
Now this takes us back to the speedo trigger wheel
It fits on the propshaft at the gearbox end
So I made a bracket to hold the pickup sensor
Lengthened the wiring loom from the axle to the gearbox and fitted the sensor
I know it looks basic but it still took quite a while to get right
Not that it matters because when I went to fit the exhaust it touches so I had to scrap that and make a new bracket (no pics)
Funny thing is it only took 20mins to make the 2nd one and it was spot on and simple
When it's up and running il see how the trigger wheel performs