G-8VXWWTRHPN DIY: overkill short throw gear shift kit - VWWatercooled Australia

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DIY: overkill short throw gear shift kit

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  • DIY: overkill short throw gear shift kit

    so, im fed up with the slop in my gear shift linkage system.. so i decided to make my own, and i spose i'll do a little write up along the way.

    my plan is to make new solid bushes, stiffer links, and steel ball joints on each end.
    i know you can buy these kits, but making it yourself is just so much more fun, and it gives me something to do.

    i've used this as a rough guide,
    VWVortex.com - USRT Smart Shift Kit - DIY/Review

    anyway..
    the other day i bought some M8 Right Angle Ball Joints, and found an off cut of Stainless Steel.
    so i knocked up these.


    next i have to make some S/S bushes just to bolt these links on, and cut two of the joints down and weld them together to make the little plastic piece that KEEPS BRAKING!!


    any questions, fire away

    '76 Golf LS Swallowtail 4dr
    '76 Golf Swallowtail 2dr
    '89 Golf GTI 16V 2dr

  • #2
    Awesome! How much for this kit?
    - Mk2 Golf GTI 16v, 2-door, Tornado Rot, BBS RS, 1988 - SOLD
    - E30 325i Coupe, Manual, Alpinweiss
    - E30 325i Touring, Manual, Diamantschwarz x 2
    - On the lookout for another E30 325i Coupe, Manual (red would be nice)...

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    • #3
      I too would like you to make me one!

      Comment


      • #4
        Awesome work, gonna keep an eye on this thread.
        And I'll stick it in the Official DIY/FAQ too.
        MK2 - *Insert list of dealer purchased extra's/standard features here*
        80 series - The MK2's BIG, Sooty, polar opposite...
        HAHAHA

        Comment


        • #5
          Originally posted by ryana89 View Post
          Awesome work, gonna keep an eye on this thread.
          And I'll stick it in the Official DIY/FAQ too.
          put me down for one as well

          Comment


          • #6
            Update:
            sprayed some copper spray in the joints, dont know if it will really do anything, but why not.


            made some aluminium bushes


            +
            =



            weighted rod fitted, and so much nicer... if you dont have a weight on this linkagem GET ONE!!! or strap a bit of steel to the original rod.

            as for making more... i'll see how this all goes, but anyone can buy the USRT kit, MissingLinkz. i couldn't really make it at a lesser cost than they do. their about $150

            '76 Golf LS Swallowtail 4dr
            '76 Golf Swallowtail 2dr
            '89 Golf GTI 16V 2dr

            Comment


            • #7
              fitted it all today... heaps better!!! nice and solid
              just need to make a few more bushes for the relay shift rod, and a delrin ball for the same rod.

              so this is what i did today.....
              started off by replicating this link.. pitch is 55mm
              needed to cut both joints down 3mm to get this pitch. to locate i just popped a bit of m8 thread in, and lock it up.

              i replaced this 6 months ago.. and it's twisted as f***, no wonder they break!!


              pulled off the bracket that connects to the g-box, now to fit these ball joints you need to cut off the balls and drill a hole through it.
              one of the aluminium bushes go in this hole.
              If you want to make a short throw kit.. this bracket can be lengthened to give you a short throw.





              next job.. unbolt and pull out the middle bracket, and again cut balls off and redrill holes.
              this bracket is only 3mm thick and was a little bent. so later on i will weld a support plate on to thicken it up.

              bolted it all up outside the car

              bolted tight in car


              now last bracket to modify..
              before you unbolt this bracket, mark its position on the shift rod (the rod that goes underneath the car to the gear stick).

              give it a clean and cut off the last ball and re-drill. with this hole i couldn't see any reason why the hole couldn't be moved, so to ensure i had enough wall thickness, i drilled the hole 3mm lower than it was originally. doesn't seem to have made a difference.

              '76 Golf LS Swallowtail 4dr
              '76 Golf Swallowtail 2dr
              '89 Golf GTI 16V 2dr

              Comment


              • #8
                after all the cutting and drilling, align and tighten it all up. then admire your handywork



                now i'm still not finished.
                on monday, ill turn up new delrin shifter ball, and nylon relay shift rod bushes.
                also need to stiffen up the middle bracket, and make a new plate for a short throw.

                '76 Golf LS Swallowtail 4dr
                '76 Golf Swallowtail 2dr
                '89 Golf GTI 16V 2dr

                Comment


                • #9
                  UPDATES!!

                  this middle bracket was slightly bent.. so sure enough i beefed it up a bit

                  bushes to go on the relay shaft. green ones are nylon, and white ball is made from acetyl.

                  how it all fits together. the original clip goes on the bottom. the circlip on the above picture slot underneath the white ball.. there is a groove for it to sit in.


                  In all seriousness.. it is amazing!!!!
                  seriously worth while to get a kit and fit it.
                  i will NOT be making anymore, sorry to disappoint anyone.

                  Just short shift plate to go

                  '76 Golf LS Swallowtail 4dr
                  '76 Golf Swallowtail 2dr
                  '89 Golf GTI 16V 2dr

                  Comment


                  • #10
                    seriously worth while to get a kit and fit it.
                    Thanks stiggy, you've just added yet ANOTHER thing to my list for "must buy" MK2 parts.
                    It looks the goods though, in particular your unnaturaly clean diff housing.
                    MK2 - *Insert list of dealer purchased extra's/standard features here*
                    80 series - The MK2's BIG, Sooty, polar opposite...
                    HAHAHA

                    Comment


                    • #11
                      Yes please I'll have one too PLEASE
                      500 Series Hino - 99 V6 PASSAT Daily Driver
                      84 MK2 GTI 16v - 88 MK2 GTI 8v Donor

                      Comment


                      • #12
                        little update on these bad boys..

                        i wasn't happy with the ball joint i had, they were unsealed and needed lubricating every now and again to keep it nice.
                        so today i changed them over for the THK sealed variant. so far so good.



                        and due to some persuasion (you all know who you are), i'm making some more sets.
                        once they're done, ill let everyone know.

                        '76 Golf LS Swallowtail 4dr
                        '76 Golf Swallowtail 2dr
                        '89 Golf GTI 16V 2dr

                        Comment


                        • #13
                          DIY: overkill short throw gear shift kit

                          Anything more to this?

                          Comment


                          • #14
                            so far they're about 70% there, ill let everyone know when they're complete.
                            just been sooooo busy lately, so these have been pushed a side. hopefully done within the next month.

                            '76 Golf LS Swallowtail 4dr
                            '76 Golf Swallowtail 2dr
                            '89 Golf GTI 16V 2dr

                            Comment


                            • #15
                              Looks like a great bit of kit mate! You've got some skill!

                              Shut up and take my money

                              Comment

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