I've nearly finished rebuilding a spare PG1 for the coupe and the final stage of the build is shimming the diff and mainshaft. Setting the clearances properly required a 0.7mm shim. Obviously these and pretty much every other size of PG1 mainshaft shim are NLA, so I had to find a way to shrink a 0.9 that I had taken out to size.
A couple of local precision engineering companies that I knew to have the correct machine for this (a magnetic bed surface grinder) told me to they weren't interested, so I present my solution:
Superglue, cable ties and, after my previous attempt at making a homemade magnetic chuck came loose at 900rpm and smacked me in the face, much blood and swearing.
For those interested* this achieved an accuracy of 0.03mm.
Mechanical engineers: Cover your eyes.
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Mechanical engineers: Cover your eyes.
Tom.
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Re: Mechanical engineers: Cover your eyes.
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Re: Mechanical engineers: Cover your eyes.
Great improvisation, Tom
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Re: Mechanical engineers: Cover your eyes.
As an ex Precision Engineer myself, congratulations. I mean the shim, not smacking yourself in the face with a spinning chuck, that was pretty foolish, to put it mildly. Dying is no way to make a living!
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