Go Back   986 Forum - for Porsche Boxster & Cayman Owners > Porsche Boxster & Cayman Forums > DIY Project Guides

Reply
 
LinkBack Thread Tools Display Modes
Old 08-17-2017, 04:51 PM   #1
Custom User Title Here
 
particlewave's Avatar
 
Join Date: Mar 2012
Location: KC
Posts: 5,883
Garage
DIY Full Bearing Short Shifter

Since Ben said that he isn't making them anymore, I thought I'd try my hand at it.

I bought a precision metal lathe, a short shifter and some bearings.
The main shaft has a roller bearing and the others have 2 SKF ball bearings each for stability (6801Z, 21mm x 12mm x 5mm).
At about $8 each, they are a bit pricey, but I didn't want to cheap out and end up with something with excessive play or that would fall apart after little use.
They are butter smooth!

The small shafts must be turned down to 12mm. I suggest stopping at 12.1mm and test fitting. You can then finish off with fine grit sandpaper and polish for a tight and smooth fit.

The cups need to be widened to 21mm, but I stopped at 20.9 for a tight press fit. I did this so that the bearings could be semi-permanently mounted in the cups and the shafts can slide into them. The bearings can still be driven out of the cups using the bolt at the rear in case they ever need replacing, but they should outlast the car.

Fun stuff!








Last edited by particlewave; 08-18-2017 at 09:33 AM.
particlewave is offline   Reply With Quote
Old 08-18-2017, 11:26 AM   #2
1999 base
 
Meir's Avatar
 
Join Date: Dec 2011
Location: Coral Springs FL
Posts: 1,579
Garage
Cool!
how the hell did you manage to hold the shaft centered in the lathe?
4 jaws chuck?
and just out of curiosity, what lathe did you get?
Meir is offline   Reply With Quote
Old 08-18-2017, 11:58 AM   #3
Registered User
 
Join Date: Jan 2014
Location: New Jersey
Posts: 1,210
What Meir said! Does the lathe have a fixture to hold the lever still while the cutting tool spins to bore the hole for the roller bearing? Is the bolt that goes through the roller bearing threaded all the way down or does it have a smooth unthreaded section to ride on the rollers? That is really cool, thanks for sharing!
PaulE is offline   Reply With Quote
Old 08-19-2017, 01:52 PM   #4
Custom User Title Here
 
particlewave's Avatar
 
Join Date: Mar 2012
Location: KC
Posts: 5,883
Garage
I did not bore the roller bearing hole on the lathe.
The shaft surface that the roller bearing rides on is smooth (polished) with threads on the ends only.

The lathe I bought is the Shop Fox mini metal lathe from Northern Tools ($600).
It was a bit more than I wanted to invest in this project, but I hope I can use it for other things. I'm going to make a few of these (at least) to try to help lessen the wallet dent.

I'll have 3 shifters ready to ship next Friday if anyone wants one. I think $135 shipped in the US is probably the lowest I can go. I'm not looking to turn a profit, so if that seems high, let me know.
particlewave is offline   Reply With Quote
Old 08-19-2017, 03:00 PM   #5
Registered User
 
steved0x's Avatar
 
Join Date: Dec 2012
Location: FL
Posts: 3,885
I have one of Ben's but I don't know if it has the roller bearing on the main shaft, how hard is that to retrofit, did you have to do any turning/sanding or was it a direct fit?
steved0x is offline   Reply With Quote
Old 08-19-2017, 03:07 PM   #6
Racer Boy
 
Racer Boy's Avatar
 
Join Date: Sep 2015
Location: Seattle, WA
Posts: 648
I'm interested. PM sent!
Racer Boy is offline   Reply With Quote
Old 08-21-2017, 07:44 AM   #7
Custom User Title Here
 
particlewave's Avatar
 
Join Date: Mar 2012
Location: KC
Posts: 5,883
Garage
..........

Last edited by particlewave; 08-21-2017 at 08:21 AM.
particlewave is offline   Reply With Quote
Old 08-21-2017, 08:21 AM   #8
Custom User Title Here
 
particlewave's Avatar
 
Join Date: Mar 2012
Location: KC
Posts: 5,883
Garage
Quote:
Originally Posted by steved0x View Post
I have one of Ben's but I don't know if it has the roller bearing on the main shaft, how hard is that to retrofit, did you have to do any turning/sanding or was it a direct fit?
You would definitely have to drill a larger hole to add one.
particlewave is offline   Reply With Quote
Old 08-22-2017, 08:03 AM   #9
Registered User
 
mavis.d's Avatar
 
Join Date: Apr 2014
Location: Leeds UK
Posts: 101
Quote:
Originally Posted by steved0x View Post
I have one of Ben's but I don't know if it has the roller bearing on the main shaft, how hard is that to retrofit, did you have to do any turning/sanding or was it a direct fit?
I have one of Ben's kits and it does have the roller bearing in the shaft.
mavis.d is offline   Reply With Quote
Old 08-22-2017, 10:29 AM   #10
Ben-Auto-Design
 
Ben006's Avatar
 
Join Date: Oct 2014
Location: French Riviera
Posts: 806
Quote:
Originally Posted by steved0x View Post
I have one of Ben's but I don't know if it has the roller bearing on the main shaft, how hard is that to retrofit, did you have to do any turning/sanding or was it a direct fit?
It does have a roller bearing

Nice one!

I'm gonna make more, that's for sure, but I have to save for a lathe first and I'm not fully settled in my new place yet (Have to make a proper workshop!).

Ben
__________________
ASE certified Automotive Master Technician.
Porsche Tech in France.
www.benautodesign.fr
Ben-Auto-Design : Performance parts for 9X6 / 9X7
2001 986 S, Manual, all black.
Ben006 is offline   Reply With Quote
Old 08-28-2017, 09:44 PM   #11
Custom User Title Here
 
particlewave's Avatar
 
Join Date: Mar 2012
Location: KC
Posts: 5,883
Garage
I have one left, then I'm done for about a month.

I'm moving on the 15th, so will be packing until then and unpacking after that. I may make more then if Ben isn't up and running yet, but I'm not sure. It's really finicky and a lot of work, so I don't know if I want to make any more.

If anyone wants this last one, let me know before the week is over. After that, it will be packed up and possibly lost forever.
particlewave is offline   Reply With Quote
Old 10-11-2017, 10:35 AM   #12
Custom User Title Here
 
particlewave's Avatar
 
Join Date: Mar 2012
Location: KC
Posts: 5,883
Garage
I have one more that had some cosmetic damage on the shifter body (scratches). I wasn't going to sell it because it looked bad, but I guess it won't be seen anyway.

I'll take $15 off for the scratches if someone wants it. $120 shipped, CONUS.

I'll post a picture or two of the scratches later today.
particlewave is offline   Reply With Quote
Old 10-11-2017, 01:46 PM   #13
Custom User Title Here
 
particlewave's Avatar
 
Join Date: Mar 2012
Location: KC
Posts: 5,883
Garage
Here it is.
Attached Images
 

Last edited by particlewave; 10-11-2017 at 01:53 PM.
particlewave is offline   Reply With Quote
Old 10-11-2017, 01:48 PM   #14
Custom User Title Here
 
particlewave's Avatar
 
Join Date: Mar 2012
Location: KC
Posts: 5,883
Garage
And the scratches...
Attached Images
 

Last edited by particlewave; 10-11-2017 at 01:54 PM.
particlewave is offline   Reply With Quote
Old 10-14-2017, 08:23 PM   #15
Registered User
 
Aggromuffin's Avatar
 
Join Date: Oct 2017
Posts: 27
Quote:
Originally Posted by particlewave View Post
And the scratches...
PMd

Sent from my SM-G950U using Tapatalk
Aggromuffin is offline   Reply With Quote
Reply


Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On




All times are GMT -8. The time now is 02:13 AM.


Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2019, vBulletin Solutions, Inc.
Content Relevant URLs by vBSEO 3.6.0
Copyright 2018 Pelican Parts, LLC - Posts may be archived for display on the Pelican Parts Website -    DMCA Registered Agent Contact Page