Shugmobile upgrade - Now with throttle linkage photos.

[Shug]

It's been a fair amount of time since one of my hair brained schemes, so methinks it's time for a thread detailing my new pikey-tastic performance enhancement to the Shugmobile. Might also balance out some of the Supercar stories floating about the forum at the minute!

Those who know me will know I've been bleating on for years about how a close ratio gearbox would be the ideal accompaniment to the Shugmobile - still on the original 92K mile PG1 (and clutch, incidentally) that has the horrible hole between 2nd & 3rd - with the top 3 being too tall for most things anyway. The Lotus CR box (B4BP) brings the ratios down and closes it all up so theoretical top speed drops, but you get usable revs for more of the time. Downside being that cruising ability is reduced - I have Shures to help with that...

So, what I've gone for, in true pikey fashion, is the best combination of low-mileage kit with minimum price. Got in contact with a bloke that was building up a close ratio gearset from a variety of boxes, picked the best he could find and then got a 4K mile old complete gearbox to build it up into. At that stage he ran out of time to do it, so whacked the gearset on Fleabay. I've managed to get the gearset and the box for a very reasonable cost (well under what you'd find a leggy CR box for anywhere) and I'm going to finish the job!

Done lots of research and I'll go through the process with pics in this thread. Have to say a huge debt of thanks to Bob (hiscot) who did all of the digging about and sent me various links to stuff for sale and build threads/manuals and personal advice. Top lad

Package arrived today, so I'll try and get photos up tomorrow

[BiggestNizzy]

Best of luck to you

Having stripped and rebuilt the gearbox in the clio (before I shipped it off to paisley to get it done right) it was a hell of a job on my parents slightly slopping driveway.

[Shug]

Best of luck to you

Having stripped and rebuilt the gearbox in the clio (before I shipped it off to paisley to get it done right) it was a hell of a job on my parents slightly slopping driveway.

PG1 is pretty simple, as gearboxes go & I have the luxury of doing this inside (well, a greenhouse) with a bench and lots of piccies

[BiggestNizzy]

Best of luck to you

Having stripped and rebuilt the gearbox in the clio (before I shipped it off to paisley to get it done right) it was a hell of a job on my parents slightly slopping driveway.

PG1 is pretty simple, as gearboxes go & I have the luxury of doing this inside (well, a greenhouse) with a bench and lots of piccies

To be honest the only bit I had real trouble with was the ball bearing dowel spring arrangement that stopped you selecting reverse you needed 3 pairs of micro hands to get it all together.

Oh that and realising I didn't have the proper puller and had to take it to someone who did

[Rich H]

*Watches with interest*

Are you going for a plain CR box or is it different ratios?

Greenhouse? Luxury...

[kenny]

Pikey methods FTW, get it done before summer or I'll lose interest and patience

[Shug]

FACKING UPS!!!!!!

They have delivered the gearbox fine - just lost, yes, LOST the bunch of CR cogs... Gladly, it's insured... Totally f**king unbelieveable...

[Rich H]

Hmm helpful. That sucks.

Lost as in terminally lost never to be seen again, or lost as in in the eather somewhere to reappear at some indetermined point?

[Shug]

The tracking report says the carton was discovered empty and discarded. Somebody's taken a liking, or they have just fallen out in a truck... Seeing how he packed the gearbox, seller may have just chucked them in a jiffy bag...

I'm bloody fuming - need to sort out with the seller now how much money I get back - will keep the box I have as it'd cost more to post back than it's worth...

Now on the search for another box, or set of ratios. Whisky has been poured...

[Rich H]

Give Olly at Phoenix a ring they alwys have loads of boxes knocking about, the workshop is full of bits after the honda installs.

[tenkfeet]

The tracking report says the carton was discovered empty and discarded. Somebody's taken a liking, or they have just fallen out in a truck... Seeing how he packed the gearbox, seller may have just chucked them in a jiffy bag...

I'm bloody fuming - need to sort out with the seller now how much money I get back - will keep the box I have as it'd cost more to post back than it's worth...

Now on the search for another box, or set of ratios. Whisky has been poured...

I would claim for the value of the whole flebay purchase as its worthless without cogs.

I have used the ebay listing as proof of value when an item went missing . Hope you get it sorted .

[hiscot]

shug can you not claim for the whole package inc post and return costs ?

[Shug]

Need to get in contact with the seller first - his inbox is overflowing. He organised the courier, so is the one the insurance covers - they were sent as 2 different packages, for weight, so claim will only be against the one that was lost.

Will speak to him first - if I can't get him or he's an arse, I'll claim the lot back through paypal (as it's how I paid him)

Don't think he's on the pisstake, just daft for not packing it right. Already contacted my second choice to see if it's still up for sale...

[Shug]

Okay - I've got one gearbox and I'm a bloke, so I might as well take it apart. Supposedly, this has a 4.2 final drive (15 tooth pinion) as opposed to the normal 3.9, 16 tooth final drive. Making sure of that is as good an excuse as I need to get it in bits.

Right, the box arrived, having had already been apart, so there are some steps missing (taking out the reverse idler shaft bolt & a few other things on the outside of the case) Also, there's a clip holding the layshaft to the top case that has already been taken off.

Here's the box as it arrived:



Take all the bolts out and a couple of good slaps with the percussion instrument and it looks like this:



Other side with selector forks:



To count the teeth on the pinion, best to take the lot out, as the pinion is buried out of sight when it's like this. 5 Bolts to take out. 2 remove the reverse selector (I held up the reverse idler with a socket to stop it wanting to move) then three on the main selector. Pic taken with reverse selector removed:



With both selectors out - it's just the cogs and the selector forks left in:



These (with some wiggling and patience) come out as a one-ner and you can place the lot down:



Now, for the job in hand. Count the pinion teeth with me, the ones closest to camera. Remember, I'm looking for 15 to make the 4.2 close final ratio. 1, 2, 3....:



14, 15..... 16...

So it's a totally standard box. Gladly, it wasn't much (was almost as much to post) As soon as I can get in touch with this guy, we'll be having a 'conversation' about this... Have another iron in the fire already for another box, which will also need modified - so this thread will continue.

On a more positive note - I got a short-shift lever from Fleabay which I fitted in the space of 10 minutes. Transforms the feel of the shift and I'd wholeheartedly recommend it. This is from someone who was reasonably happy with the shift in my car as well!

Looks like this is gonna be another saga...

[BiggestNizzy]

That box doesn't look to bad to work on, a hell of a lot easier than the clio it had either 4 or 5 spindles full of cogs.

I have a gearbox off a metro gti (think it's the same one) should you need any bit's your welcome to it. It is a close ratio box as well but I don't think it can stand up to the same punishment as it was off a 95bhp car.