Club 80-90 Forums

Is there a bolt somewhere to the right of the hole that you could run a bracket/plate from? Bracket doesn't need to be that thick as it's just to stop the bolt slipping sideways and hold it in position when you tighten it and with a decent washer on the back broken lug it should still provide the support needed.

muttleypup wrote: ↑18 Jul 2025, 07:04 Is there a bolt somewhere to the right of the hole that you could run a bracket/plate from? Bracket doesn't need to be that thick as it's just to stop the bolt slipping sideways and hold it in position when you tighten it and with a decent washer on the back broken lug it should still provide the support needed.

Not really unfortunately.  The gearbox is in the way one side and nothing much to the other side.

I have considered drilling next the lug and pinning a sturdy washer in place but don't want to risk weakening what remains of the lug so that that breaks off too.

 

I had thought that as well but the bolt option seemed easier. Can’t see you have anything to lose by trying it. Rather than a washer, maybe make a pair of plates the same shape as the lug and drill two holes either side at the base where there’s more metal to play with.

Flat bar (red) same width as the lug around the lug, bolted (purple) into the meat of the lug away from the hole. That's how I would tackle it.

Good ideas.  I don't currently have a tap & die set to form new holes for the holding bolts but might need to get one.

 

Update.

So on second viewing I noticed not only was there a handy bolt but it was also right next to the problematic bolt hole/lugs - amazing what you don't see if you're not looking for something. So I cut and drilled a metal plate to bridge between the two bolts - easy peasy.  I've not extensively tested this but should hold.





However, it turns out that is was not really the cause of my gear problem.  I think it popping out was symptomatic of the real problem which was the gear linkage bars were set too far apart.   After many frustrating hours I finally got it working acceptably.  Fingers crossed it doesn't drop out again!


 

https://brickwerks.co.uk/product/gear-l ... ase-saver/

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ajsimmo wrote: ↑21 Jul 2025, 17:42 https://brickwerks.co.uk/product/gear-l ... ase-saver/

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You're joking!!  Wish I'd known about that a few weeks ago!