Prop shaft reverse gear

After sourcing a gear of the correct size and tooth design dad set about mating it to the prop. The supplied gear was 25mm thick and weighed 3kg. Obviously we dont need the gear to be anywhere near this thick, so after turning the centre out to the correct side to slid over the hardy spicer  (which was alos turned down to give a mounting sleeve), dad split it into 2 gears. I now have a spare and a lighter gear. Rtaher than welding the gear onto the prop, dad used a flange off a Freelander Viscous coupling unit, turned it down and welded it to the hardy spicer. With the flange welded on, it was put back in the lathe and faced off again to ensure it was true. A small recesses was also machined out of the gear so it fits perfectly onto the new flange. The gear was then simply bolted in place.

On sunday i picked up the sump and we dropped the engine in place and have decided that we can mount the engine using 2 aluminium plates, hanging the engine off the 4 main engine mounts and then use 2 stabilising bars from the top lugs of the engine (copied from Bobs BDN design). The engine was then pulled out again and all the body work fitted ready to be shipped off to the Mechanex show at Sandown park on Tuesday. The car will be back on thursday, and hopefully the chassis mods started on friday, watch this space......