>Date: Thu, 27 Aug 1998 15:45:37 -0500
>To: morris@autox.team.net
>From: Ray McCrary <spook01@mindspring.com>
>Subject: Part 2 Morris 5 speed
>
>Hello again,
>
>Once I got the trans home, I cleaned it up with a combo of easy off oven
cleaner with a final wash with aluminum siding cleaner.
>
>This gave me a good clean part to begin to modify.
>
>I began with closing off ALL openings to the workings of the trans with
200 mph tape and begin a large pie shaped cut in the top of the bellhousing.
>
>This is required to clear the steering rack, and allows the trans to be
removed without removing the engine for ease with the next clutch job.
>
>This cut was easily accomplished with a carbide blade in a saber saw, and
after polishing the edges of the cut, a piece of sheet aluminum was cut and
shaped to cover the hole, with the aid of a template that came in the kit.
The plate was secured with 1/4" #8 sheet metal screws (supplied).
>
>Next,the vent tube on the top of the trans was bumped with a rubber hammer
to bend it down closer to the top of the trans. This for more room over
the top of the trans.
>
>The backup light and emmission control switches on the side of the trans
were removed, and their holes plugged. This for clearance on the side.
>
>I then screwed the adaptor plate to the trans and traced around the edges
with an awl. The point of this is to remove a couple of protuberances that
would interfere with the fit of the starter/trans/frame. The starter sits
slightly lower on the rear engine plate in order to better align with the
Datsun trans and is pretty close to the "frame" on this side.
>
>It also looks better, for the anal amongst us.
>
>This operation was accomplished with a high speed rotary sander using an
aggressive grade of aluminum oxide pads.
>
>I then took the supplied template and bolted it to the starter mount holes
in order to cut a starter drive clearance hole in the bellhousing. A 3/8"
long drill bit was inserted in a pre-drilled hole in the template, and a
pilot hole was cut into the trans. From the rear of the bellhousing, a 1
3/4" holesaw allowed drive clearance.
>
>To be sure of fit, the starter was then bolted up to the plate.
>
>The old drive cover was unscrewed from the (junk) ribcase and modified
slightly (with snips) to cover the new hole in the Datsun trans. It was
then screwed into position, making sure of its clearance around the starter
bendix.
>
>The oil pump cover plate was fitted into the new rear engine plate and a
slight relief ground into the interior of the bellhousing using a Dremel
tool.
>
>One hole on the left (remember, this is a left hand drive car) bottom of
the trans (these bolts hold the front and rear of the trans together) was
enlarged to 5/16" to accommodate a bracket that forms part of the clutch
actuation mechanism.
>
>Paul sent new seals, front and rear, for the trans; these were popped into
position.
>
>The new throwout bearing (supplied) was then pressed onto its hub, and
then returned to its position. As part of this operation, the clutch TO
bearing arm was extended with the supplied part.
>
>Morriservice rewelds your original shift stick to the bottom of the Datsun
stick. This allows the stickshift to use the stock boot and remain
unobtrusive. Some of the Datsun shifters resemble strange walking sticks!
>
>After all, the goal is to have a stock appearing car that cruises at
higher speeds with less fuss!
>
>The last mod is to the car itself: Just behind the large right-side
eyebolt nut in the "frame" (this is the point where the right lower control
arm is secured), the flange where the two halves of the "frame" are spot
welded together is bent down to offer more room for the starter. This was
down with a body hammer and dolly.
>
>During our conversation, and also during our e-correspondence Paul had
stressed the close clearance around the starter, so I was sure to take
particular care in this area.
>
>I broke out the Binks paint gun at this point to touch-up the area that I
had worked.
>
>All of the above took me one afternoon, and two bottles of Theakston "Old
Peculiar"!!!
>
>So far, I am VERY pleased with my kit....
>
>Next, reuniting the engine and trans.
>
>Regards,
>Ray
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