DIY: overkill short throw gear shift kit

[moostin]

Yes please I'll have one too PLEASE

[Stiggy_21]

little update on these bad boys..

i wasn't happy with the ball joint i had, they were unsealed and needed lubricating every now and again to keep it nice.
so today i changed them over for the THK sealed variant. so far so good.



and due to some persuasion (you all know who you are), i'm making some more sets.
once they're done, ill let everyone know.

[ozgti]

Anything more to this?

[Stiggy_21]

so far they're about 70% there, ill let everyone know when they're complete.
just been sooooo busy lately, so these have been pushed a side. hopefully done within the next month.

[Goon]

Looks like a great bit of kit mate! You've got some skill!

Shut up and take my money

[ausgolfer]

To anyone wanting to buy one off the shelf. I can recommend the missinglinkz kit. Have had it in my 16v for about 8 years and never had a problem with it

Same as your kit Dave, but without the newer "sealed" ball joints you've since added. As I said, I've never had a problem with the regular ball joints that came in my kit.

Ps not knocking your great work Dave. If I had the skills I'd love to make one myself too.

[CPITUNING]

Nice write up, so how was the end result? Major difference? Again great write up and awesome pics

[Watercooled]

Nice work,have done the same but used 8mm rose joints very expensive even @ mates rates but there have bronze inners and after 3 years still good.
Like the way you beefed up the weak parts,I replaced my golf ball roller as you have done and worked better than the NOS one before that.
Any improvement with the weighted relay rod? haven't made one as yet.
Mine is also been short-shifted and feels firm but very positive.

[Stiggy_21]

Nice write up, so how was the end result? Major difference? Again great write up and awesome pics

cheers guys

TBH haven't actually driven the mk2 in a while, new toys are too much fun

at first i had changed the standard bushes over with the standard bush replacement kits readily available.
and it wasn't much better.

but after i installed this kit in, i did noticed a big difference. It gives a more mechanical feel, therefore less chance for gear slips (assuming you still have 2nd syncro)

some of the sloppiness comes from the 'ball' (looks like a skateboard wheel). The original VW product consists of an inner plastic piece and a rubber-like exterior sleeve.
When this ball sits in its 'cup', there is about a 1mm gap side to side. By making this out of a harder material (acetal), and reducing the gap to as minimal as possible, mine was within 0.2mm, it reduces the chance for slop.
However, most of the slack throughout the system is caused by the factory ball joint arrangement.
By installing solid ball joints and solid bushes, it eliminates this factor.
Rubber or Plastic bushes tend to distort from the side loads they are subjected to from shifting gears, and over time they will wear out.

As i've said previously, the best ball joints i've found are the THK ones. They are widely used in the automotive industry... and yes they are the most expensive part minus the labor.

With the weighted rod, my one weighed in at 1kg, but i reckon its a tad too heavy. I've made another one at 800g, but yet to test it.
with this, when shifting through gears, just adds a weighted feel and much nicer to drive.


some people may think it is a bit overkill, but it is something that can be punished and will last!!