T5 aly with a 152 polini conversion.

[jackson85]

Fecking T5 and the chocolate casings

[fastfrog]

A blo.dy crystal glass....

[johnd]

I think Oz who has a TS1 on T5 casings has strengthened that area with and extra bolt on the clutch cover. one either side of the primary axle, for more strength. An idea?

[fastfrog]

I've seen this transformation. Very nice job. Anyway casing is too thin at this very place. It needs to be almost doubled to insure more strengh.

[Fruitjuice]

Question is how deep the recess is inside the primary gearstack...
Find somebody with a lathe that can turn you a new longer primary shaft.The cylindrical bit going through the casing would need to be about 1,5 to 2 inches longer.
Shouldn' be too difficult, it's not a hardened shaft. Don't worry about the keyway in the threads.
Weld a pre-drilled piece of aluminium (same diameter as the existing hole) to the casing next to the existing primary shaft hole and it'll never break again. You wouldn't even need to fix the existing crack.
Then just put a grub screw through the top of the aluminium bit to keep the shaft from rotating.
You could even go as far as to make a small chamfer at the end of the aluminium bit and fit a small O-ring to seal it all.

[fastfrog]

Quite difficult I guess. People usually just weld and fix the crack (hum hum don't misunderstand me!)

[OzOAP]

[ducksta]

i do like that anybody offering to do one for me if i send the clutch housing

[sean brady scooters]

i do like that anybody offering to do one for me if i send the clutch housing

you would obviously need to do the main casing at the same time dont forget ! lol

[fastfrog]

+1