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The Builder
About Builder
Builder Last Online: Nov 2020
Model Scale: 1/8
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Started: 03-22-11
Build Revisions: Never
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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!
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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