We were contacted by Gordon with a strange request, having had continual issues with his rebuilt automatic gearbox, he opted to convert it to manual. The problem is, manual VR6 gearboxes are in short supply, and those available are getting on in the years and may not hold up to the rigours of daily driving and towing the race car at weekends.
Now, this is seemingly something most people shy away from, but we got stuck in anyway. With plenty of measuring, a bit of headscratching, we produced drawing and waterjet cut a 10mm aluminium adapter plate.
Great, but that's where the easy bit ends. We didn't have an engine to measure and check against, only the original auto gearbox, and with the plate in place, the mounts and drive shafts would no longer function as Volkswagen intended.
With chosen gearbox stripped, the mating face was then machined down the correct depth to allow everything to align properly, the adapter plate was then machined further to add clearance in the tighter areas left by the bellhousing modifications.
All hardware was sourced, then cut and made to the correct length before being returned to Gordon for him to fit to the vehicle.
With some minor fettling and a starter motor change, he is now up and running with a strong manual gearbox and off to compete this weekend at Craigantlet Hillclimb in his fantastic Fiat X1/9
