THE GEARBOX COVER MOD - SELF BUILD ONE
THIS PROJECT COVERS THE ALUMINIUM GEAR COVER (Upgrading the plastic one)
I missed out a section of photographs so apologies for that but you will get the idea.

NOTE: WHEN FIXING THE FRONT PLATE PLEASE NOTE THAT THE METHOD SHOWN BELOW
IS THE ONLY WAY OTHER THAN ALUMINIUM WELDING.
THE METHOD BELOW ENSURES THAT THERE ARE NO PARTS THAT COULD FALL INTO YOUR
GEARING IF THEY WORKED LOOSE.

WE START WITH A STRIP OF ALUMINIUM (FIG-01)
The strip is 5cm wide to allow for the bottom tab and fixing tabs.
It is also 33cm long.

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The first thing is to bend the strip into the right shape, i recommend giving AT LEAST
5-10mm clearance all round because if you bash it its going to dent in and grind your gears!
NOTE: MAKE SURE YOUR STRIP MEETS AT THE 2 BOLTS AT THE TOP BY THE BRAKE SHAFT

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OK NO PHOTO FOR THIS PART SO CLOSE YOUR EYES AND IMAGINE..... lol

Whilst holding the strip in place mark the BOTTOM piece out to bend over for the 2 bolt holes.
Once they are marked you need to cut off 10mm down one side up to where you marked the bottom piece as shown in FIG-01.
Now you should have a stuck out tab about 50-60mm long.
This tab needs bending OUTWARDS.
Then place the cover back in position and mark the holes out through the back of the support bracket at the bottom.
Drill out these holes then put the cover back in position and screw & tighten the cover on from the bottom.

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Whilst its fixed at the bottom, pull the strip around to the meeting point.
NOTE: YOU MAY NEED TO CUT A NOTCH OUT OF THE STRIP FOR IT TO MEET
When you are happy that its meeting ok you need to mark out the top 2 bolt holes (just about shown above with nuts on)
Now that they are marked, drill the holes whilst its still attached to the car.. AND put on the nuts and tighten down.

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THE FRONT PLATE TABS

Ok you now need to cut with tin snips about 7mm into the outer edge as shown in red above.
Make these cuts all the way around the edge, then cut of every second tab so they bend inwards properly.

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THE FRONT PLATE

RIGHT!: - You need to remove the strip from the car and put it against a piece of aluminium plate.
Mark around the shaped strip and cut it out.
When you have the cutout shape you need to place the plate on the front of the strip and drill out holes.
The holes need to be about 1-2mm so that you can screw self tapping screws into them.
READ THE NEXT PART CAREFULLY!
THE SCREWS YOU USE SHOULD NOT BE ANY LONGER THAN 6mm!
DO NOT BE TEMPTED TO USE NUTS & BOLTS BECAUSE IF THEY WORK LOOSE
AND ONE GETS INTO YOUR GEAR SPROCKETS YOU WILL BE REPLACING MORE
THAN JUST THE GEARS!
SEE BELOW FOR AN IDEA OF THE SCREW LENGTHS

There is about 2-3mm showing through the other side.
I THOUGHT LONG AND HARD OF A WAY TO FIX THE FRONT PLATE TO THE BODY.
APART FROM ALUMINIUM WELDING THIS APPEARS TO BE THE ONLY WAY TO
FIX THE PLATE WITHOUT ANY DANGER OF A STRAY SCREW LOOSENING AND
FIRING INTO THE GEAR SYSTEM.

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SO THIS IS WHAT YOU SHOULD HAVE WHEN YOUR FINISHED.
ADDITIONALLY YOU COULD TAP THE GAPS IN THE EDGES CLOSED WITH A HAMMER.
ALSO IT WILL NEED A GOOD POLISH WHEN COMPLETE.
JUST FOR ADDED SAFETY I PUT A DROP OF SUPERGLUE ON THE BACK OF ALL THE SCREWS.