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T-5 transmission project
Goal amount for this year: 518 USD, Received: 415.00 USD (80%)
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T-5 transmission project T-5 transmission project T-5 transmission project T-5 transmission project T-5 transmission project
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    1. Kit: , by (VIP/Sponsor) gbritnell is offline
      Builder Last Online: Jan 2019 Show Printable Version Email this Page
      Model Scale: 1/8 Rating:  Thanks: 0
      Started: 03-22-11 Build Revisions: Never  
      Not Supported

      While planning for this winter's project I had several ideas in mind. Last winter was the V-twin so this year although I had several other engines in mind I wanted something a little different.
      I had been over to my son's house and while helping him in the garage I noticed a T-5 transmission laying over in the corner. The T-5 is a 5 speed manual transmission built by Borg-Warner and used in a variety of vehicles, not the least of which is the Ford Mustang.
      Now I already have the 302 engine so why not build a working trans for it?
      The first step or should I say the first of many steps was to clean and disassemble the trans. Next up was to sketch and measure all of the parts (reverse engineering at it's finest.) With that done, or at least thinking it was done I started Cad drawings of the whole affair. I ended up with around 14 sheets in 8-1/2x11 format. I could have done them larger but that's the size of my printer. I could have PDF'd them and taken them to the local copy store but I have found from past projects that there's always many dimensions missing and details that need correcting when the build starts.
      The drawings were still in progress when the first chunk of aluminum was started. This was to be the main case.
      As with any machining project that entails complex shapes a plan of attack needs to be formulated so there's always something to clamp on to.
      All of the holes were put in first, main shaft, countershaft, drain hole, shift shaft hole etc. Then came the digging out of the inside. The hardest part was making the long cuts with ball end mills. They really like to dig in so you have to watch the cutting direction at all times.
      Both sides were done next while leaving the bottom area square . That way I could clamp from front to rear or top to bottom to set up angular surfaces for machining. The last machining was the bottom.
      For developing radii on the many shapes I have become quite proficient at what I learned in patternmaking. That is referred to as sine and cosinining or mathematically stepping over and down to form the desired radius. Some radii can be produced on a rotary table but the setup time in some cases makes it easier to do it the other way.
      With Cad available I just draw the radius that I want, offset the cutter radius and then put my coordinate step in.
      The last part of the process is burring and stoning all the machine marks out then going in with small files, jewelers and rifflers to smooth everything out.
      I think I ended up with around 120 hours on the case.
      George
      I have loaded the pictures to the machining gallery but am unsure how to sequentially add them to my thread. Help!
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  1. gbritnell's Avatar VIP/Sponsor
    Name
    George
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    Jul 2006
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    213
    The following 3 pictures show the case with all the machining complete. Just the benching to do.
    George



    QUOTE QUOTE #17

  2. gbritnell's Avatar VIP/Sponsor
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    George
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    The first 2 pictures show the case with all the burring and stoning complete. The finish is just with fine grade emery paper.
    The last 2 pictures show the finished cases bolted together.
    George





    QUOTE QUOTE #18

  3. gbritnell's Avatar VIP/Sponsor
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    George
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    To answer a question, the scale is 3 tenths. A little less than a third made all the dimensions even.
    Here's a comparison of the full sized gear box with it's little brother.
    George

    QUOTE QUOTE #19

  4. Giovanni's Avatar Established Member
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    Giovanni
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    Jan 2011
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    What a brilliant job!


    Regards,
    Giovanni
    QUOTE QUOTE #20

  5. Toner283's Avatar Member
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    Chris
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    Oct 2006
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    6
    Wow! I have rebuilt several T5's for myself and other folks and this is amazing. A picture of that case would fool anyone who knew T5's into thinking they were looking at the real thing unless you told them how big it actually is.

    I can't wait to see the rest of the project.
    Don't worry, I've done this a lot, nothing bad ever happens...
    QUOTE QUOTE #21

  6. hot ford coupe's Avatar VIP/Sponsor
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    Jeffrey
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    Sep 2005
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    Brilliant. Simply brilliant. A veritable masterpiece.
    Sometimes a handful of patience is worth more than a truck load of brains. Have the courage to trust your own beliefs. Don't be swayed by those with louder voices. W.S. Maugham :)
    QUOTE QUOTE #22

  7. gbritnell's Avatar VIP/Sponsor
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    George
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    Here's an update to the trans project. I found a little time between other jobs and got the top cover machined. Although it's a smaller part it has a lot of angular ribs and curved surfaces both inside and out, so there is quite a bit of time involved not only with machining but setup. Yesteday I also got the input shaft housing machined. This completes the machining part of the cases and covers. All that remains is to bench the tooling marks out and then I can move on to the internals, gears, shafts and linkages. These will be much simpler than the cases because they won't have all the detailing work. The first set of photos show the top cover from the outside and inside showing all the machining. There are two shots of the cover installed onto the main case and one showing the detailing on the input housing.
















    George
    QUOTE QUOTE #23

  8. Don Garrett's Avatar Asst. Administrator
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    Don
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    Too cool for words George.......;';;';
    Grandpa McGurk.....Steppin' Large and Livin' easy.
    TDRinnovations.com
    QUOTE QUOTE #24

  9. Andym's Avatar VIP/Sponsor
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    Andy
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    592
    Stunning. Absolutely fantastic!

    I'm in awe George.

    Andy.
    When I was young I used to say "When I grow up I'm going to be somebody!"

    I now realize I should have been more specific.
    QUOTE QUOTE #25

  10. xken's Avatar VIP/Sponsor
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    Kenneth
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    Aug 2008
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    George,

    Looking great as ever. Which aluminum alloy are you using for the case?

    Don't you just love the smell of hot T-5 transmission project cutting fluid in the morning!

    Ken
    QUOTE QUOTE #26

  11. gbritnell's Avatar VIP/Sponsor
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    George
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    Hi Ken,
    Nothing exotic, just 6061 aluminum. It's just about the standard for making most parts. I occasionally use 7075 which cuts a little cleaner but it's more expensive.
    George
    QUOTE QUOTE #27

  12. BrassBuilder's Avatar Yearly Subscriber
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    Mike
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    Jan 2007
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    I'm interested in the math involved to cut the rounded areas. IIRC, you are doing all of this on a manual mill and not using a rotary table. I've been picking up what I can on running my own mill.

    Absolutely stunning work.

    Mike
    My website:
    http://www.firesteelhobbies.com/index.html

    Feel free to look around. I have all of my projects on the website.
    QUOTE QUOTE #28

  13. gbritnell's Avatar VIP/Sponsor
    Name
    George
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    Jul 2006
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    Thanks Mike,
    The way to cut the radii by hand is by stepping of the radius. When I learned it as an apprentice it was called sine/cosine. These are the triangular mathematical functions for developing a circle. Starting at the very top centerline of a circle you would call this X-0-, Z-0-. Now you move out a specified distance and down a specified distance and make a cut. These cuts are the equivalent of the wanted radius plus the radius, or centerline, of the ball mill being used. You try to make the steps small enough so that there isn't a lot of hand work to do but at the same time not so small that it takes forever to cut them.
    I do use my rotary table for cutting radii but generally these are arcs that are developed in a flat plane.
    George
    QUOTE QUOTE #29

  14. Deuces-wild's Avatar VIP/Sponsor
    Name
    Guido
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    Dec 2005
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    2,209
    Starting to look like the one I have in my '91 5.8L Mustang..
    Be nice or else ~1~**
    QUOTE QUOTE #30

  15. gbritnell's Avatar VIP/Sponsor
    Name
    George
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    Jul 2006
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    213
    One in the same.
    QUOTE QUOTE #31

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