DIY: overkill short throw gear shift kit

[Stiggy_21]

so, im fed up with the slop in my gear shift linkage system.. so i decided to make my own, and i spose i'll do a little write up along the way.

my plan is to make new solid bushes, stiffer links, and steel ball joints on each end.
i know you can buy these kits, but making it yourself is just so much more fun, and it gives me something to do.

i've used this as a rough guide,
VWVortex.com - USRT Smart Shift Kit - DIY/Review

anyway..
the other day i bought some M8 Right Angle Ball Joints, and found an off cut of Stainless Steel.
so i knocked up these.


next i have to make some S/S bushes just to bolt these links on, and cut two of the joints down and weld them together to make the little plastic piece that KEEPS BRAKING!!


any questions, fire away

[Domel]

Awesome! How much for this kit?

[straight_fresh]

I too would like you to make me one!

[ryana89]

Awesome work, gonna keep an eye on this thread.
And I'll stick it in the Official DIY/FAQ too.

[kinezo]

Awesome work, gonna keep an eye on this thread.
And I'll stick it in the Official DIY/FAQ too.

put me down for one as well

[Stiggy_21]

Update:
sprayed some copper spray in the joints, dont know if it will really do anything, but why not.


made some aluminium bushes


+
=



weighted rod fitted, and so much nicer... if you dont have a weight on this linkagem GET ONE!!! or strap a bit of steel to the original rod.

as for making more... i'll see how this all goes, but anyone can buy the USRT kit, MissingLinkz. i couldn't really make it at a lesser cost than they do. their about $150

[Stiggy_21]

fitted it all today... heaps better!!! nice and solid
just need to make a few more bushes for the relay shift rod, and a delrin ball for the same rod.

so this is what i did today.....
started off by replicating this link.. pitch is 55mm
needed to cut both joints down 3mm to get this pitch. to locate i just popped a bit of m8 thread in, and lock it up.

i replaced this 6 months ago.. and it's twisted as f***, no wonder they break!!


pulled off the bracket that connects to the g-box, now to fit these ball joints you need to cut off the balls and drill a hole through it.
one of the aluminium bushes go in this hole.
If you want to make a short throw kit.. this bracket can be lengthened to give you a short throw.





next job.. unbolt and pull out the middle bracket, and again cut balls off and redrill holes.
this bracket is only 3mm thick and was a little bent. so later on i will weld a support plate on to thicken it up.

bolted it all up outside the car

bolted tight in car


now last bracket to modify..
before you unbolt this bracket, mark its position on the shift rod (the rod that goes underneath the car to the gear stick).

give it a clean and cut off the last ball and re-drill. with this hole i couldn't see any reason why the hole couldn't be moved, so to ensure i had enough wall thickness, i drilled the hole 3mm lower than it was originally. doesn't seem to have made a difference.

[Stiggy_21]

after all the cutting and drilling, align and tighten it all up. then admire your handywork



now i'm still not finished.
on monday, ill turn up new delrin shifter ball, and nylon relay shift rod bushes.
also need to stiffen up the middle bracket, and make a new plate for a short throw.

[Stiggy_21]

UPDATES!!

this middle bracket was slightly bent.. so sure enough i beefed it up a bit

bushes to go on the relay shaft. green ones are nylon, and white ball is made from acetyl.

how it all fits together. the original clip goes on the bottom. the circlip on the above picture slot underneath the white ball.. there is a groove for it to sit in.


In all seriousness.. it is amazing!!!!
seriously worth while to get a kit and fit it.
i will NOT be making anymore, sorry to disappoint anyone.

Just short shift plate to go

[ryana89]

seriously worth while to get a kit and fit it.

Thanks stiggy, you've just added yet ANOTHER thing to my list for "must buy" MK2 parts.
It looks the goods though, in particular your unnaturaly clean diff housing.