second gear stuffed

[Camel]

I've undercut a few Busa 2nd, 3rd gears. Recently did a set for a K6 engine from an off-road buggy. These things hammer hard, particularly on the gears.



They also bend the shift forks...


...usually because the shift fork shafts flex so easily. I've pulled apart a box where the shaft was still flexed by partially dislocation of the shift fork pin. gently levered it to one side and it popped back in - pulled it apart, checked the shaft and it was straight!

Here's the standard shaft, look how thin they are!



Here's the tool steel shafts:



I usually replace the shift fork shafts with tool steel jobbies because they don't flex. I also check the cases because with the shafts flexing they tend to oval out their support boss holes in the cases.



A few months back I had to undercut a guys 3/4 gear dogs between heats ( an all saturday night special). The dogs were pretty bad (another buggy) and I had to take heaps of meat off. So much so that I advised him not to use it and skip the following days event. He was keen so I put it in and he had no problems. I've been trying to get him to replace the gear but he's still racing with it! I've got a photo of it somewhere, too embarrassed to post it!

Camel