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T-5 transmission project
Goal amount for this year: 518 USD, Received: 160.00 USD (31%)
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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
    Join Date
    Jul 2006
    Posts
    213
    After much assembly, disassembly, fitting and filing I finally have the reverse/overdrive shifting mechanism working like it should. It's one thing to make a drawing but when you are machining by hand it only takes a couple of thousands here and there to impede the proper functioning. With this finished I can move on to the main shift levers.
    George


    QUOTE QUOTE #47

  2. hot ford coupe's Avatar VIP/Sponsor
    Name
    Jeffrey
    Join Date
    Sep 2005
    Posts
    7,826
    George, every time my ego gets the better of me, I just watch one of your engine videos and my humility is restored. Your work never ceases to amaze me. You build scale miniatures and replicas. I make plastic toys.
    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 #48

  3. jamewatson's Avatar Active Member
    Name
    Jame
    Join Date
    Jun 2011
    Posts
    15
    Hey gbritnell, you have done a great work, I heartly appreciate of your work, it is really very nice job, I like it very much, thanks for sharing a nice pics of your work.
    QUOTE QUOTE #49

  4. gbritnell's Avatar VIP/Sponsor
    Name
    George
    Join Date
    Jul 2006
    Posts
    213
    Hopefully the SMC pictures will get back in the thread but for the time being I'll post the remaining photos from my Photobucket account.
    The trans is finished and working as it should. The first pictures are of the finished gearbox. Not as interesting as looking inside and seeing all the gears but still quite unique. I have made the reverse sending unit for the side of the case and the neutral switch for the top cover.
    Hopefully this winter I can pull the engine apart and drill the crank for the pilot bearing along with making the clutch and pressure plate assembly. The shifter was copied from a Hurst unit that I have. The shifting mechanisms turned out to be the most intricate pieces of the build. There is a gate block in the floor of the shifter box that directs the block attached to the shift rod. Along with the gating there are also detent holes that a spring loaded bearing pops into. This need to be located 'exactly' as it had to match the selector mechanism inside the transmission. After a lot of fine adjustments with set screws I was then able to drill, ream and pin the shifter block in place.
    Also attached is a link to Youtube showing the shifting operation of the trans.
    George








    QUOTE QUOTE #50

  5. xken's Avatar VIP/Sponsor
    Name
    Kenneth
    Join Date
    Aug 2008
    Posts
    2,321
    George,

    This is some mighty awesome work, most people cannot appreciate the amount of work that has gone into this. I was really looking forward to seeing this at Glenmoor.
    Keep up the great work!

    Ken
    QUOTE QUOTE #51

  6. hot ford coupe's Avatar VIP/Sponsor
    Name
    Jeffrey
    Join Date
    Sep 2005
    Posts
    7,826
    Good Gravy, George. I'm lucky to be able to find the transmission let alone build a miniature working one. That's absolutely incredible. I for one can really appreciate what you're doing here. Heck, if I ever get shrunken down to 1/8 scale by an angry wizard, I'm coming to you to build me a car so I can get around.
    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 #52

  7. Ton's Avatar VIP/Sponsor
    Name
    Ton
    Join Date
    Mar 2008
    Posts
    1,092
    It is one of the most awesome projects with the less commands, a winner in all its aspects and a hidden treasure so to say
    QUOTE QUOTE #53

  8. Toner283's Avatar Member
    Name
    Chris
    Join Date
    Oct 2006
    Posts
    6
    I have been offline for quite a while and have only just seen the finished project. looks amazing. I have rebuilt several t5's and yours is a dead on match. I wish I had skills like yours.
    Don't worry, I've done this a lot, nothing bad ever happens...
    QUOTE QUOTE #54

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