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saved this as a sticky for anyone interested in making their own one
yes basically it was 00sid that made the first brace for the box which worked to an extent but did have flaws in its design.
kieron aka yellow weapon came up with a great idea of making a figure of 8 brace between the input and lay shaft to stop them pulling apart which would have been great on a drag car but not so clever on road car as you would have to lose 5th gear and it still never stopped the shaft punching through the bellhousing end.
my idea was much much simpler and would have worked around 5 years back now.
heres the idea as im not gonna bother producing these now but I carried out a lot of tests with a press and gearbox endcases we had in stock and it makes the endcase 5-6 times stronger fact!
all you need to do the job is some engineering swarf, fibreglass matting and some resin/hardener.
I made a mould for these but think I lost it when we moved to our bigger unit but you don't really need a mould if its just for your own box.
basically what youll need to do is coat the entire end of the box in resin about 4'' down from the end (this is the weak point) but before you coat it youll need to cover it in talcum powder, flour or grease so the resin does not actually stick to the box as such.
give it around 3 heavy coats then app[y fg matting then another coat of resin then add some swarf into the resin mix.
you need to build it up so its around 10mm thick all round and so all the voids right at the back of the end casing are completely filled with resin/matting.swarf.
once you've done this you should be able to tap the whole thing off the endcase, but it will be tight as its a glovelike fit.
once you have done that you will notice that there are 2 unused threaded bolt holes right at the end of the casing so you need to drill 2 holes through the fibreglass glove in order to fit 2 bolts make a 5mm steel or aluminium plate then attach the glove over the endcase then bolt the holder plate on top
that's it job done!
although the casings break from the inside out it will help hugely in strengthening the case.
simple way of looking at it is by this..............imagine you have a sheet of glass say 18''sq and lets say 3mm thick, now if that was in a frame you could punch this with your fist and smash it easily, but now put a 10mm sheet of fibreglass, swarf, resin directly behindf the sheet so its butted up tight then try break the sheet of glass with your fist........youll break your hand before you break the glass, so that was the theory and it does work.
however none of the above will stop the gearset punching through the bellhousing where the bearing is and tbh I don't know how you could remedy that not without designing a whole new thicker billet housing which is the reason I did not go ahead with mass producing the ready made fg endcase supports.
but as said earlier the volume that do actually break through punching bearing through bellhousing are few and far between anyway and even if it does happen at least your gearkit isn't sprawled all over the track in a thousand pieces lol
yes basically it was 00sid that made the first brace for the box which worked to an extent but did have flaws in its design.
kieron aka yellow weapon came up with a great idea of making a figure of 8 brace between the input and lay shaft to stop them pulling apart which would have been great on a drag car but not so clever on road car as you would have to lose 5th gear and it still never stopped the shaft punching through the bellhousing end.
my idea was much much simpler and would have worked around 5 years back now.
heres the idea as im not gonna bother producing these now but I carried out a lot of tests with a press and gearbox endcases we had in stock and it makes the endcase 5-6 times stronger fact!
all you need to do the job is some engineering swarf, fibreglass matting and some resin/hardener.
I made a mould for these but think I lost it when we moved to our bigger unit but you don't really need a mould if its just for your own box.
basically what youll need to do is coat the entire end of the box in resin about 4'' down from the end (this is the weak point) but before you coat it youll need to cover it in talcum powder, flour or grease so the resin does not actually stick to the box as such.
give it around 3 heavy coats then app[y fg matting then another coat of resin then add some swarf into the resin mix.
you need to build it up so its around 10mm thick all round and so all the voids right at the back of the end casing are completely filled with resin/matting.swarf.
once you've done this you should be able to tap the whole thing off the endcase, but it will be tight as its a glovelike fit.
once you have done that you will notice that there are 2 unused threaded bolt holes right at the end of the casing so you need to drill 2 holes through the fibreglass glove in order to fit 2 bolts make a 5mm steel or aluminium plate then attach the glove over the endcase then bolt the holder plate on top
that's it job done!
although the casings break from the inside out it will help hugely in strengthening the case.
simple way of looking at it is by this..............imagine you have a sheet of glass say 18''sq and lets say 3mm thick, now if that was in a frame you could punch this with your fist and smash it easily, but now put a 10mm sheet of fibreglass, swarf, resin directly behindf the sheet so its butted up tight then try break the sheet of glass with your fist........youll break your hand before you break the glass, so that was the theory and it does work.
however none of the above will stop the gearset punching through the bellhousing where the bearing is and tbh I don't know how you could remedy that not without designing a whole new thicker billet housing which is the reason I did not go ahead with mass producing the ready made fg endcase supports.
but as said earlier the volume that do actually break through punching bearing through bellhousing are few and far between anyway and even if it does happen at least your gearkit isn't sprawled all over the track in a thousand pieces lol
Last edited by GTI-R US on 15th September 2013, 9:48 pm; edited 1 time in total
I didn't know that, I'll soon find out 
