Just a preview of another whacky tool build for a specific job.
I only partially solved the gearbox noise the last time I had it out. Partially in that I worked out the problem...the error was in my re-installation...
In order to speed things up, I modified our TINY press at work (Ross's personal press) and made a HUGE version. I've reinforced this one in various ways you can't see. The specs of parts and dimensions should meet the 6 tonne capacity of the bottle jack.
So now I can put the entire gearbox directly into the press, no problem. Last time was a big kludge nightmare. This is so much better.
In order to correct a previous error (and damage to an internal bearing), I need to "pull" the input shaft into this bearing, NOT press them. The difference is subtle. When the input shaft is assembled against the remainder of the drive-train that it's connected to, a smaller bearing that it locates onto between the two parts is crushed if I apply force through the entire gear-train. I need to pull JUST this nose-cone-input-shaft through the heavy bearing, and lightly "push" the remaining gear-train up behind into the back of the input shaft as it's pulled into the larger bearing...easy...
Of course I'd just use tool LDV126 and LDV127 if they supplied it to the public...
Here I've made the part you can see in the top left corner of the workshop manual image.
It's more obvious to identify in your head when you see it cut open like this (as is the original tool, no, the image is not just a cut-away image...the tool is actually split)
Over 40 minutes of reaming/scraping with the tip of a hand file got this to fit snugly. I had limitations on what I could do with the lathe at work as we're not a fitter-and-turner operation.
I've made up the additional collars and slide-tube for the completion of this tool though they're not shown here. I have yet to ream out the second half of this tool part before attempting to use it. ...who knows... I have a few ideas up my sleeve if this fails horribly.
As mentioned in the previous photo, here you can see the reamed out half, and the untouched half that I have yet to work on. There difference is 1.5mm all-round. Quite a lot of scraping required!!
