Snapped 5-speed lever? Here's how to repair it.
Posted: 09 Sep 2012, 11:03
Disclaimers first: This is a techniquqe that I have used for several RHD 14mm gear levers. All were reasonably straight up until the time of fracture, if yours has swan-necked (knuckles into the radio etc) then you will have extra straightening to do before following this guide!
You will require: approx. 590mm or 23 1/4" of 8mm bright mild steel rod.
A welding plant with decent output (disposable bottle toys are not up to the task)
Angle grinder
Files/drill burrs
Large copper/hide mallet
Bench vice or 4"x2" timber offcut
OK here's the familiar scene:
Mark the position of the collar grub-screw, so you can line up the two halves for welding. Grind/file the broken ends to a weld prep. of approx. 70 degrees included angle for best results. Remove all traces of plating from both the gear-knob end of the lever and inside the fork end/drilled hole with file/burrs.
Holding the upper part of the lever upside down in a vice or resting on a wood block, drive the steel rod down into the lever until flush with the end. It will follow the curve of the lever suprisingly easily if a whiff of grease is applied to the rod:
Slide the lower half of the lever onto the rod and clamp. Alignment will be tricky due to metal stretching etc. but this can be dressed off post-weld:
Tack in position once happy that it's as good as it can be - remember to line them up!
Remove all traces of grease at top end and plug weld both ends:
Return to the site of the fracture and fully weld:
Dress welds smooth and re-dimple for the grub screw. Put it back in the van. Job done!
You will require: approx. 590mm or 23 1/4" of 8mm bright mild steel rod.
A welding plant with decent output (disposable bottle toys are not up to the task)
Angle grinder
Files/drill burrs
Large copper/hide mallet
Bench vice or 4"x2" timber offcut
OK here's the familiar scene:
Mark the position of the collar grub-screw, so you can line up the two halves for welding. Grind/file the broken ends to a weld prep. of approx. 70 degrees included angle for best results. Remove all traces of plating from both the gear-knob end of the lever and inside the fork end/drilled hole with file/burrs.
Holding the upper part of the lever upside down in a vice or resting on a wood block, drive the steel rod down into the lever until flush with the end. It will follow the curve of the lever suprisingly easily if a whiff of grease is applied to the rod:
Slide the lower half of the lever onto the rod and clamp. Alignment will be tricky due to metal stretching etc. but this can be dressed off post-weld:
Tack in position once happy that it's as good as it can be - remember to line them up!
Remove all traces of grease at top end and plug weld both ends:
Return to the site of the fracture and fully weld:
Dress welds smooth and re-dimple for the grub screw. Put it back in the van. Job done!
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